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MISTRAL AMERICA

40 - 45 - 50
TRAINING MANUAL
P/N 3676163M1 - EDITION 07-2004
INTRODUCTION

This manual refers to tractor MISTRAL AMERICA 40 - 45 - 50 manufactured by LANDINI S.P.A.. It is divided into
sections identified by numbers with three/four figures. The pages of each section are numbered separately.
- The subjects described are listed in the general index and appear in more detail in the specific index of the section
in question.
- The date of the relative edition/update is printed at the bottom of each page.
- Pages where future updates are made will have the same print number but the new date of issue.
These pages will be supplied by a reprint of the duly updated index.
- The information in this manual was up to date on the date printed on the page. Since LANDINI constantly
updates its range of products, some of the information could no longer be up to date following modifications made
for technical or commercial reasons, or to adapt the machines to the laws in force in the various countries of use.
Consult our Dealers and Assistance Centres if discrepancies are found.

LIABILITY

LANDINI S.p.A. declines all liability for incorrect servicing operations, use of spurious spare parts and tampering
with parts of the product.
The person in charge of the personnel is responsible for ensuring that the safety regulations described in the manual
are applied. This person must be qualified to carry out the operations required, be familiar and strictly comply with the
prescriptions in this manual and the general safety regulations applicable. Failure to comply with the safety regulations
may lead to persons being injured and damage to machine components.

PURPOSE OF THE MANUAL

This manual is mainly dedicated to workshop staff.


This manual contains all the necessary technical information concerning the machine, allowing the servicing technicians
to work in safety and guarantee that the product remains perfectly efficient throughout its working life. However, it is
not a substitute for thorough professional training.
To correctly carry out the servicing activities, it is assumed that the place of work conforms to the current standards
governing safety and hygiene.
This manual contains all the information required to correctly carry out modifications, tune ups, repairs and overhauls.
Read this manual carefully before proceeding with any work. Correct repairs are guaranteed and the operators
safeguarded from accidents by compliance with the instructions supplied and by using the right tools.

The illustrations and descriptions in this publication are purely indicative.


The Manufacturer reserves the right to make any modifications to the machines considered necessary at any moment
for improvement purposes or for manufacturing and marketing requirements, without being obliged to give prior
notice.

LANDINI S.p.A.
VIA G. MATTEOTTI, 7 - 42042 FABBRICO (RE) - ITALY
PRINTED S/N 3676163M1 - EDITION 07-2004
COMPILED BY SST s.r.l. - TURIN
TABLE OF CONTENTS

Section N Edition
1 GENERAL INFORMATION
General information...................................................... ................ 100 07-2004

2 ENGINE

Engine......................................................................... 07-2004
................ 200

3 CLUTCH
Clutch......................................................................... ................ 300 07-2004

4 GEARBOX
(12 + 12) and (16 + 16) Mechanical gearbox................... ................ 400 07-2004

5 TRANSMISSION
Rear differential axle..................................................... ................ 500 07-2004
Front axle.................................................................... ................ 510 07-2004

POWER TAKE-OFF
6
Power take-off.............................................................. ................ 600 07-2004

7 HYDRAULIC CIRCUITS
Hydraulic circuits - Rear power lift................................... ................ 700 07-2004
Hydraulic circuits - Auxiliary control valves....................... ................ 710 07-2004

STEERING SYSTEM
8
Steering system........................................................... ................ 800 07-2004

9 BRAKES
Brakes........................................................................ ................ 900 07-2004

ELECTRICAL SYSTEMS
10
Electrical system - Instruments....................................... ................ 1000 07-2004
Electrical system - Components...................................... ................ 1010 07-2004
Electrical system - Ignition system.................................. 07-2004
................ 1020
Electrical system - Recharging system............................. ................ 1030 07-2004
Electrical system - Battery............................................. ................ 1040 07-2004

Electrical system - Electrical circuits................................ ................ 1050 07-2004


GENERAL INFORMATION

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SECTION100 - GENERAL INFORMATION <L

INDEX

Description Page

SAFETY NOTES............................................................................................................................ 100-3


Personal risk .....................................................................................................................100-3
Avoid accidents ................................................................................................................. 100-3
General rules..................................................................................................................... 100-3
Starting............................................................................................................................ 100-5
Engine.............................................................................................................................. 100-5
Electrical systems............................................................................................................... 100-5
Hydraulic circuits ...............................................................................................................100-5
Wheels and tyres................................................................................................................100-6
Splitting and remounting parts.............................................................................................100-6

GENERAL INSTRUCTIONS ............................................................................................................100-7


Battery ............................................................................................................................ 100-7
Adjuster shims................................................................................................................... 100-7
Spinning shaft seals ...........................................................................................................100-7
"O-ring" seals.................................................................................................................... 100-7
Bearings ...........................................................................................................................100-7
Spring pins .......................................................................................................................100-7
Notes about spare parts .....................................................................................................100-8
Specific equipment.............................................................................................................100-8

SYMBOLS .................................................................................................................................. 100-9


Meaning and use ...............................................................................................................100-9

DANGER SIGNS.........................................................................................................................100-11
Positions of the danger decals - WEO markets ......................................................................100-11
Positions of the danger decals - NAO markets.......................................................................100-16

SEALING AND FIXING SEALANTS ................................................................................................100-21

LUBRICANTS AND FUELS............................................................................................................ 100-22

CONVENTIONAL UNITS OF MEASUREMENT....................................................................................100-23


Units of measurement (international system) .......................................................................100-23
Conversion values for Imperial measurement system.............................................................100-23

STANDARD DRIVING TORQUE VALUES .........................................................................................100-24


Screws with metric threads................................................................................................100-24
Nuts with metric threads....................................................................................................100-25
SECTION100 - GENERAL INFORMATION

SAFETY NOTES
Personal risk
This warning symbol draws your attention to mes- sages
that are important for your safety.
Read the safety notes carefully and comply with the
recommended precautions to avoid potential dan- gers
and safeguard your health and personal safety.
This symbol appears in the text along with the fol- lowing
key words:
WARNING - To warn of unsuitable repair opera- tions
with potential consequences that could affect the repair
technician's safety.
DANGER - To indicate warnings that specifically denote
potential dangers for the operator's safety or for other
directly or indirectly involved persons.

Avoid accidents
The majority of accidents that occur in workshops are caused by failure to comply with some simple and fun-
damental rule of caution and safety. This is why ACCIDENTS CAN BE AVOIDED IN MOST CASES: all that's
needed is to foresee the possible causes and consequently act with due care and caution.
However well a machine is designed and built, it is never possible to absolutely exclude all hazardous situa-
tions.
A careful and prudent mechanic is the best guarantee against accidents.
Strict compliance with even only one elementary safety rule would be sufficient to avoid many serious acci -
dents.
DANGER. Never carry out any cleaning, lubricating or servicing operations whilst the engine is running.

General rules
- Carefully comply with the prescribed maintenance and repair procedures.
- Never wear rings, wrist watches, jewellery, loose or flapping garments such as, for example: ties, torn
clothing, scarves, unbuttoned jackets or with open zip-fasteners that could become caught in moving
parts. You are advised to wear approved safety garments, such as: non-slip footwear, gloves, safety gog-
gles, helmets, etc.
- Never carry out repair work on the machine whilst someone is sitting in the driver's seat, unless this per-
son is an authorized operator who is helping with the operations in progress.
- Only operate the machine and use the relative implements when you are sitting in the driver's seat.
- Do not carry out any work on the machine when the engine is running, unless this is specifically pre-
scribed.
- Stop the engine and make sure that the pressure has been relieved from the hydraulic circuits before
removing any caps, covers, valves, etc.
- All servicing work must be carried out with the utmost care and attention.
- Ladders and platforms used in workshops or in the field must comply with the current safety regulations.
- Disconnect the batteries and label all the controls to warn others that work is being carried out. Block the
machine and all implements that must be raised.
- Do not check or fill fuel tanks, batteries, or use ignition fluid when smoking or near naked flames as these
liquids are inflammable.
- The brakes are disengaged when released by hand for servicing work: in these cases, the machine must
be kept under control by means of chocks or similar.

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SECTION 100 - GENERAL INFORMATION

- The fuel pump nozzle must always remain in contact with the filier: Keep it there until you finish filling so as to
prevent sparks from being created through an accumulation of static electricity.
- Only use the prescribed hitching points when towing. Make the connections with care: make sure that the provided
pins and/or latches are firmly fixed in place before beginning to tow. Keep well away from tow bars, ropes or
chains that are pulling a load.
- If possible, use a trailer or truck with a lowered loading platform when transferring a faulty machine.
- When a machine must be loaded on to or unloaded from the transport vehicle, choose flat ground able
to provide a solid bearing surface for the wheels of the trailer or truck. Fasten the machine to the truck or trailer
platform firmly and block the wheels as required by the haulage contractor.
- Only use auxiliary power sources with grounding circuits able to prevent electric shocks for electric heat- ers,
battery chargers and similar equipment.
- Use hoists and similar equipment with an adequate carrying capacity if heavy parts must be lifted or transported.
- Pay particular attension to bystanders.
- Never pour petrol or diesel fuel into wide and shallow open vessels.
- Never use petrol, diesel fuel or other inflammable fluids as detergents: use the nonflammable and non- toxic
solvents available in the shops.
- Protect your eyes by wearing goggles with side guards when using compressed air to clean parts.
- Limit the pressure to 2.1 bar at most, in compliance with the local or national laws in force.
- Do not run the engine in a closed room without adequate ventilation.
- Do not smoke, use naked flames or create sparks in the vicinity when refuelling or handling easily inflammable
materials.
- Do not use flames as a means of lighting when repairing the machine or searching for "leaks".
- Move with the greatest care when working under, on or near the machine. Wear the recommended safety
garments: a helmet, goggles and special safety footwear.
- When the engine must be running in order to make the inspections, ask for help from an operator who must
remain in the driver's seat and keep the mechanic under visual control at all times.
- If servicing is required away from the workshop, park the machine on flat ground and block it. If work on slopes is
unavoidable, block the machine and move it to a horizontal surface as soon as this can be done within a certain
safety margin.
- Do not use crushed or bent chains or ropes: when lifting or towing are required. Always wear suitably thick gloves
to handle them.
- Chains must be firmly fixed in place: make sure that the fastening is sufficiently strong to bear the load in
question. Have all bystanders move well clear of the connection, chains or ropes used for lifting or towing.
- The area where the servicing operations are carried out must always be kept CLEAN and DRY. Puddles or water or
oil stains must be cleaned up immediately.
- Do not form heaps of rags soaked in grease or oil: they could catch fire very easily. Always put them in a closed
metal container.
Check, regulate and lock the driver's seat before starting the machine or implements. Make sure that there are no
bystanders within the range of action of the machine or implements.
- Do not carry objects in your pockets that could drop unseen into the internal mechanisms of the machine.
- Wear goggles with side guards, helmets, special safety footwear and gloves when you could be struck by metal
objects and similar, thrown up during the servicing work.
- Use the necessary safety protections when welding operations are carried out: dark glasses, helmets, dungarees,
special gloves and footwear. Dark glasses should also be worn by the people not actually doing the work but who
are in the vicinity when welding is being carried out. NEVER LOOK AT THE WELDING ARC WITHOUT ADEQUATE EYE
PROTECTION.
- Metal ropes become frayed with wear: always protect yourself in an adequate way when handling them (wear
gloves, goggles, etc.).

100-4 P/N3676163M1 Edition07-2004


SECTION100 - GENERAL INFORMATION

- Handle all parts with the utmost care. Keep your hands and fingers well away from gaps, wheelwork and
similar. Always use approved personal protection devices such as safety goggles, gloves and safety foot-
wear.

Before you get on to the tractor, it is essential for you to have read and strictly com-
plied with the instructions in the operation and maintenance manual.
Starting
- Do not allow the engine to run in a closed room without adequate ventilation systems able to dispose of
the exhaust gas.
- Never put your head, body, limbs, feet, hands or fingers near spinning fans or belts.

Engine
- Before removing the radiator plug completely, turn it very slowly to relieve the pressure in the circuit.
Coolant fluid must only be topped up with the engine at a standstill or idling, if hot.
- Do not refuel whilst the engine is running, particularly if it is hot. This could lead to the risk of a fire out-
break if fuel were to be spilt.
- Do not attempt to check or adjust the tension of the fan belts with the engine running.
Do not regulate the fuel injection pump whilst the machine is on the move.
- Never lubricate the machine when the engine is running.

Electrical systems
- If auxiliary batteries must be used, remember that the cables must be connected in the prescribed way at
both ends: (+) with (+) and (-) with (-). Do not short-circuit the terminals. THE GAS ISSUED BY BAT-
TERIES IS HIGHLY INFLAMMABLE. Always leave the battery housing uncovered when recharging, to ensure
a more efficient ventilation. Never ever check the battery charge using the "jumpers" obtained by placing
metal objects on the terminals. Prevent sparks or flames in the battery area. Do not smoke as this could
cause explosions.
- Before proceeding with any work, make sure that there are no fuel or electricity leaks: repair these leaks
before proceeding.
- Do not recharge batteries in closed places: make sure that there is adequate ventilation to prevent acci-
dental explosions from occurring due to an accumulation of the gas issued when recharging.
- Always disconnect the batteries before working on the electrical system.

Hydraulic circuits
- Fluid leaking from a very small hole can be almost invisible yet have sufficient force to penetrate under the
skin. Use a piece of cardboard or wood if you must check for such leaks. NEVER CHECK FOR LEAKS WITH
THE HANDS: immediately seek medical help if fluid penetrates under the skin. Serious infections or
dermatitis may occur if you fail to receive prompt medical treatment.
- Use the right tools to check the pressure in the circuits.

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SECTION100 - GENERAL INFORMATION <L

Wheels and tyres


- Make sure that the tyres are correctly inflated to the pressure indicated by the manufacturer.
Periodically check the rims and tyres to make sure that they are not damaged.
- Keep to the side of the tyre when correcting the inflation pressure.
- Only check the pressure with the machine unloaded and the tyres cold, to prevent incorrect measure-
ments and overpressures. Do not reuse repaired wheel parts as badly made welds, brazing or heating
could have weakened them and cause breakage.
- Never cut or weld a rim with a tyre mounted and inflated.
- Block the machine at the front and rear on all wheels before demounting these latter. After you have
jacked up the machine, prevent it from dropping by placing supports underneath, in compliance with the
current laws in force.
- Deflate the tyres before removing any objects jammed between the treads.

P/N3676163M1 Edition 07-2004 100-5


- Never inflate the tyres with inflammable gas. This could lead to explosions and injure bystanders.

Splitting and remounting parts


- Lift and handle all heavy parts with lifting equipment of an adequate capacity. Make sure that the parts are
supported by appropriate harness and hooks. Use the lifting eyelets provided. Take care of bystanders
near the load being lifted.
- Handle all parts with the utmost care. Do not put your hands or fingers between one part and the next.
Wear approved safety garments such as goggles, gloves and safety footwear.
- Do not twist metal ropes or chains. Always wear safety gloves when handling cables or chains.

GENERALINSTRUCTIONS

IMPORTANT

WARNING
All the maintenance operations and repairs described in this manual must be carried out by
the LAN DI NI assistance network only, in strict compliance with the indications given and
using special tools if necessary.
Anyone who carries out the described operations without strictly complying with the instruc-
tions becomes personally responsible for any consequent damage.

Battery
Before proceeding with any work, disconnect and insulate the negative battery cable unless other instruc- tions
are given for the specific operation required (for example: an operation where the engine must be run- ning).
After the operation has been terminated, detach this cable in order to finish the work.

Adjuster shims
Whenever adjustments are made, select the adjuster shims by measuring them one by one with a microme-
tre and then adding the values gauged: do not trust in the erroneous measurement of the complete pack or in
the nominal value given for each ring.

Spinning shaft seals


Comply with the following instructions to correct mount the spinning shaft seals:
- before they are mounted, allow the seals to soak for at least half an hour in a bath of the same type of oil
as the one they will be sealing;
- thoroughly clean the shaft and make sure that its operating surfaces are not damaged;
- position the sealing lip towards the fluid. If the lip is the hydrodynamic type, the direction in which the
scoring points (considering the direction in which the shaft spins) must tend to make the fluid flow towards
the internal part of the seal;
- spread a film of lubricant (oil is preferable to grease) on the sealing lip and fill the gap between the seal ing
lip and dust guard lip of double-lipped seals with grease;
- fit the seal into its housing by pressing or use a punch with a flat contact surface. Never hit the seal with a
hammer or mallet;
- when a seal is mounted, make sure that it is inserted perpendicular to its seat. After mounting, make sure
that it touches the supporting ridge (if applicable);
- to prevent the seal lip from being damaged by the shaft, fit an adequate guard whilst the two parts are
being assembled.

"O-ring" seals
Lubrificate the O-RING seals before they are fitted into their seats to prevent them from rolling around
themselves and becoming twisted as they are mounted, something that would compromise their sealing
ability.

Bearings
It is advisable to proceed in the following way when mounting bearings:

100-6 P/N3676163M1 Edition07-2004


- heat them to 80 - 90 C before fitting them on to their respective shafts;
- cool them before externally fitting them into their seats.

Spring pins
When mounting split tube spring pins, make sure that their notches point in the direction of the force exer-
cised on the pin itself.
Spiral spring pins do not need to be set in any direction when mounted
Notes about spare parts
Only use genuine LANDINI spare parts as only these are able to guarantee the same quality, life and safety as
the original components mounted on your machine.
Only genuine LANDINI spare parts can provide this guarantee.
Give the following information when ordering spare parts:
- tractor model (commercial denomination) and chassis number;
- engine type and number;
- order number of the required part, which can be found in the "Spare Parts Catalogue", according to which
the orders are fulfilled.

Specific equipment
The equipment that LANDINI proses and illustrates in this manual is:
- explicitly researched and designed for work on LANDINI tractors;
- necessary for reliable repairs;
- carefully made and thoroughly tested to provide efficient and long-lasting tools.
Repairers should also remember that using the right equipment means:
- working in technically optimum conditions;
- obtaining the best result;
- saving time and effort;
- working in greater safety.

P/N3676163M1 Edition 07-2004 100-7


SECTION100 - GENERAL INFORMATION

SYMBOLS

Meaning and use


Certain symbols are used in this manual to underline and draw the reader's attention to certain particular
aspects of the description, or to indicate the type of operation being illustrated.
The meanings of the various symbols used are described in the table below.

SYMBOLS MEANING NOTES

Indicates a danger with the risk of even mortal


Warning: accident for the user.
personal risk Pay the utmost attention to the texts indicated with
this symbol.

Indicates a danger with the risk of damage to the Warning: environmental hazard
natural environment. Pay the utmost attention to
the texts indicated with this symbol.

Warns that the machine or some other personal


property of the user could be damaged.

Indicates a warning, a note about key functions or


some other useful information.

This indication means that there is a considerable


risk of damage to a part, e.g. when the wrong tool
Prevent damage to material
is used or an assembly made by means of an
incorrect procedure.

Special tool/ A special tool or specific equipment must be used


specific equipment for the operations.

A visual inspection must be made. The user must


Visual observation read a measurement value, check an indication,
etc...

The operator must listen to a noise made when the


Listen machine operates. The inspection serves to identify
abnormal noise.

Symbol associated with a value: use a torque


Tighten and torque
wrench to suit the value given.

Symbol associated with two values: use a torque


Torquing with angle wrench to suit the value given and measure the
dwell angle at that torque value.

Operation carried out in order to obtain precise


Adjustment/Regulation
values (pressure, preload, relative distance, etc.).

Operation carried out in order to measure a value


Measuring/Gauging required to restore optimum functional conditions in
the correct way.
SYMBOLS MEANING NOTES

r-$ Lubrication Lubrication (oiling, greasing, etc...) of a part/ device.

Sealing/Glueing Sealant required in order to couple two parts together.

4 Positioning Coupling with relative position references.

< LANDINI Spares.


Indicates that only LANDINI spare parts must be
used.

Q DANGER SIGNS

If a tractor part bearing a decal with a safety note (yellow colour) is replaced, it is ESSENTIAL to affix the same decal to the spare part.
A complete list of all the places where decals are applied is given below.

Positions of the danger decals - WEO markets


2LA0732

Positions of the danger decals


Complete set of danger decals WEO 4203959M91
SECTION 100 - GENERAL INFORMA TION

REF. CODE POSITION DESCRIPTION SYMBOL

WARNING:Danger of electric shock.


Positioned near the Always disconnect the negative bat tery
A
1 3647 158 M1
battery cover. terminal before removing the battery or
before servicing the electri- cal system.

/
2 3559 556 M1
WARNING:Danger of entangle- ment.
Positioned on the Keep your hands well clear of the fan
left and right sides blades when the engine is running.
w\
of the radiator. Always keep the guards and screens

^.0
mounted.

*0
WARNING: Very hot surfaces. The

0-f

hands and fingers could be scorched.
Warning: keep well clear of hot parts.
Keep at a safety distance.
Positioned on both

A
3 3559 559 M1 sides of the WARNING:Danger of entangle- ment.
radiator. Keep your hands well clear of spinning
parts. Take care not to become
entangled in the belts or pul- leys whilst
the engine is running. Keep the guards

uP
in place.

*0
SECTION100- GENERAL INFORMATION

REF. CODE POSITION DESCRIPTION SYMBOL

DANGER. Jets of hot steam or hot


water.
Positioned under
Protect the face. The radiator will be
4 4203 963 M1 the cover of the
under pressure when the engine is hot.
radiator plug.
Remove the plug with caution when the
engine is cold.

DANGER. The tractor could overturn


and crush the chest. Hold firmly on to
Affixed to the
5 3559 557 M1 the steering wheel if the tractor is
bonnet.
overturning. DO NOT leave your seat or
jump out of the tractor.

WARNING: Take care. Consult the


Affixed to the operation and maintenance manual for
6 3559 558 M1
dashboard. information about safety and how to use
the tractor.

WARNING: Danger of overturning and


crushing.
Always keep the safety frame mounted.
NEVER work, NEVER remove, NEVER
overturn, NEVER bend, NEVER repair
Affixed to the and NEVER con- nect any implement to
7 3647 033 M1 safety frame on the safety frame. When necessary, only
footstep tractors. lower or remove the safety frame for
servicing work. In this case, drive with
the utmost care as the frame will no
longer provide any protection.
SECTION 100 - GENERAL INFORMA TION

REF. CODE POSITION DESCRIPTION SYMBOL

DANGER.Danger of entanglement.
Keep well away from spinning shafts.
Positioned on the Take care NOT to get caught up by the
8 3559 553 M1 inside of the left PTO driveline.
mudguard. Keep all the guards mounted on the
transmission shafts of the tractor or
implements.

Affixed to the
WARNING:Danger of being crushed.
safety frame on
9 3648 447 M1 Always wear the seat belt when the
tractors with seat
belts. safety frame is in the vertical position.

On the rear left


mudguard on WARNING:Danger of being crushed.
tractors without DO NOT allow anyone to sit on the
10 3647 032 M1
2nd passenger seat mudguards or on any other part of the
and for tractors tractor or towed implements.
with safety frames.

WARNING:Danger of being crushed.


Before leaving the tractor
unattended, apply the parking brake,
lower the implement,
On the left mud-
11 4203 962 M1 stop the engine and remove the igni-
guard.
tion key. If the engine must be left
running, apply the parking brake, lower
the implement and move the reverse
shuttle lever to the neutral position.
SECTION100- GENERAL INFORMATION

REF. CODE POSITION DESCRIPTION SYMBOL

WARNING: Risk of causing damage.


Positioned near
Read the operation and maintenance
12 3647 157 M1 the dashboard or
manual before proceeding with any
battery.
work on the tractor.

WARNING: Electrocution.
Always disconnect the negative battery
On the starter
13 3559 555 M1 terminal before removing the cover of
motor.
the solenoid and before serv- icing the
electrical system.

DANGER.Danger of being crushed. DO


NOT start the engine by shorting across
the terminals of the starter motor. This
On the starter
14 3648 152 M1 operation will place your life in danger.
motor.
Only start the engine when you are
sitting in the driving seat.
0^
SECTION100 - GENERAL INFORMATION <L

Positions of the danger decals - NAO markets

2LA0733

Positions of the danger decals


Complete set of danger decals NAO 3558702M95
SECTION100- GENERAL INFORMATION

REF. CODE POSITION SYMBOL

A DANGER
Shield Explosive Avoid sparks Sulphuric eyes gas and flame acid

Located near the EXPLOSIVE GASES POISON causes severe bums


1 3558 711 M1 Always shield eyes and face from battery.
battery cover. Cigarettes, flames or sparks could cause battery Contains sulphuric acid. Avoid contact with skin,
to explode. eyes or clothing.
Do not charge or use booster cables or adjust In event of accident flush with water and call a
post connections without proper instructions or physician immediately.
training. Keep out of reach of children.

rT
A WARNING

Located on right Beware hot parts

and left-hand side


2 3558 706 M1

ap
of radiator, or on
K
the air conveyor.

To avoid personal in-


jury, keep all shields,
covers and guards in
place whili engine is
running.

A WARNING

Located right and


3 3558 712 M1 left-hand side of
radiator.

Keep hands clear of fan


and belts while engine
is running.

AWARNING
Located near the
4 3558 708 M1 Hight pressure steam and hot
battery cap. A WARNING
water.

h-
Remove filler cap with
extreme care.

2
0^
SECTION100 - GENERAL INFORMATION

Wheneverclearance permits:
Keep Rollover Protection Structure fully extended
REF. CODE POSITION and locked. SYMBOL
- Keep seat beltSerious
fastened.
personal injury or
machin damage may
Located inside result from overspeed of
cab on the left
When structurePTO AmustWARNING
be lowered:
driven equipment.
- Drive with extra care.
Select tractorRotating
PTO speeddriveline con-
hand pillar or on Pull belt
Seat onlyusefrom match tactimplement
istonotapprov-
recommended. mayNocause
ROPS serious
edprotection
drawbar is specified
provided
or lower injury
in the
speed. or death.
lowered position.
the
Located
Locatedrearatfender
on the
rear of Keep all driveline, tractor
links of 3-pointDo not operate
linkage at andPTO above
for
cab
safety
footstep
on the
ROPS rear
trac-
for Nominal Maximum
recommended
horizontal position or place
equpment
540
maximum sheilds in
630 during operation.
6
5
7 3558 053
3647 710 M1
704 fender.
footstep
tors.
tractors. ADANGER
below.
speed.
1000 A
1170 DANGER
SECTION100- GENERAL INFORMATION

REF. CODE POSITION SYMBOL


WARIMING
Persona! injury could result from PTO driveline separation.
1. Drawbar supplied provides standard distance "A. Do not change.
Located at rear of PTO SHAFT SIZE DISTANCE "A
cab on the inner
8 3558 709 M1 540 35mm (1.38 in) 356mm (14.0 in)
*---------
side of the left 1000 35mm (1.38 in) 406mm (16.0 in)
2. Three-point link distance "C and mounter implement distance "D may not be standard.
fender.
Measure distance "B over complete lift range for tractor
and implement combination. Select driveline length to
ensure that driveline will not bottom out at minimum
distance "B and will have sufficient overlap at maximum
distance.

Located inside
cab or on the
9 3558 707 M1
right fender for
footstep tractors.
SECTION 100- GENERAL INFORMA TION

REF. CODE POSITION SYMBOL

A CAUTION

Read the operator instrue-


tion Book for safety infor-
mation and operating in-
struetions.
Fasten your seat belt be- fore
traetor operation.
Start engine only when
seated in operator's seat.
Make sure everyone is elear
of traetor and equpement
before starting engine or
operation.
Keep all shields, eovers and
guards and plaee and stay
away from moving parts while
engine is run- ning.
Plaee transmission shift le-
Located inside ver in neutral and apply
parking brake before us- ing
cab or on the left-
10 3558 703 M1 external 3-point hiteh
hand fender for eontrols.
Apply parking brake, lower
platform tractors. equpment, stop engine and
remove key before leaving
the traetor unattended.
Wait for all movement to stop
before servieing trae- tor or
equpment.
Seeurely support or bloek
lifted implements whieh must
be in the raised po- sition for
servieing or ad- justment.
Couple brake pedals to-
gether for road travel.
Use flashing warning lights
and SMV emblem when on
publie roads, exeept where
prohibited by law.
Always drive with eare and
attention.

A WARNING
Remove negative ca- bles
Located on the
11 3558 705 M1 from batteries before
starter motor. removing solenoid cover
and before servicing the
electrical system.

ADANGER
Located on the Start only from seat with
12 3648 153 M1 transmission and PTO in
starter motor.
neutral.

Starting in gear kills.


SECTION100 - GENERAL INFORMATION

SEALING AND FIXING SEALANTS

Apply the sealants given in the table to the surfaces to couple.


Prepare the surfaces in the following way before applying the sealants:
- remove any deposits with a metal brush;

locking
- thoroughly degrease the surfaces with one of the following detergents: trichloroethylene, wash oil or water
and soda.

and couplings
DENOMINATION TYPE USE

sealing
Weak locking and sealing of screws, adjuster
Weak locking Loctite 222
Threaded screws.

Medium-strong locking and sealing of threaded


Medium-strong thread locking Loctite 242
parts in general.

Highly resistant fixing, locking and sealing of


Strong thread locking Loctite 270
stud bolts, nuts, screws.

Capillary locking and sealing of already


Penetrating thread locking Loctite 290
mounted parts. Microporosity sealing.

Locker Loctite 601 Highly resistant fixing of coupling surfaces.


Smooth couplings

Medium-strong resistance fixing of bushes,


Fixer Loctite 641 bearings, etc. Demounting possible using
normal tools.

Highly resistant fast fixing of cylindrical parts.


Super-locker Loctite 638
Dynamic work.

Fast fixing of cylindrical parts highly resist- ant


High-temperature locker Loctite 648
Hydraulic

to heat.
unions.

Sealing of threaded unions on hydraulic or


Hydraulic-hermetic Loctite 542
pneumatic pipes up to %" in diameter

Pipe-hermetic Loctite 572 Sealing of threaded unions in general.


EngineSealing of

Thick flat-hermetic Loctite 510 Sealing of flat surfaces. Manual application.


surfaces

Sealing of precise flat surfaces. Applied by hand


Flat-hermetic Loctite 573
or by screen-print systems.

Hermetic plastic - spray type Sealing of cylinder head surfaces.


Perkins power
part hylomar
Hermetic - paste type Sealing of sump surfaces, covers.
10 LUBRICANTS AND FUELS
0-
22 Quantity dm3
P (litres)
/
N MISTRAL Specifications SINCLAIR MOBIL ESSO SHELL BP LAND OIL AGIP
3 Component AMERICA Ambient
6 supplied temperatur S
7 40 45 50 E
6 C
1 HY VIS HD EXTRA TI
6 S3 Plus 10 W Essolube D / 3 RIMULA CT Oil 10 BP Vanellus C3 10 DIESEL SIGMA O
SAE CD Below 0C DELVAC 1310 HDL S3 10 W
3 Plus 10 W W W 10W N
M 1
1 0
Ed API CD - SF Essolube D / 3 RIMULA CT Oil BP Vanellus C3 HDL S3 20 W DIESEL 0
from 0 to 27C DELVAC 1320
iti API CE - SF HY VIS HD EXTRA Plus 20 W 20 W 20 W SIGMA 20W -
20 G
on S3 Plus 20 W 20
07 E
- MIL-L-2104D Essolube D / 3 RIMULA CT Oil 30 BP Vanellus C3 30 N
20 Engine with filter 4.7 5.8 5.8 Over27C DELVAC 1330 HDL S330 DIESEL SIGMA 30 E
MIL-L-2104E HY VIS HD EXTRA Plus 30 W W W
04 S3 Plus 30 R
A
Essolube XD / 3 BP Super tractor UNILAND 15 W SIGMA TURBO L
CCMCD2/D4 Universal Farm
EXTRA Oil Universal 40 UMITRACOTR S I
N
SUPERLAND SUPER
F
Any HY VIS HD EXTRA Mobiland Super
Unifarm -
O
Oil Shell Agrarna UNIVERSAL15 W TRACTOR
temperatur S3 Plus 15 W 40 Universal R
40 UNIVERSAL M
Change ^
A
steering and
hydra ulic Torque fluid 62 LOT OTRAS/B ROTRA
Any TRANSFLUID
circuits and rear 24 24 24 API GL 4 MF 1135
temperatur AS/B Mobilfluid 422 (1) Donax TD (1) Tractran 8 (1)
fina drives. MULTITHT
(1) (1)

Front axle and Any HD GEAR OIL MOBILUBE GX 90


front fina drives API GL 5 MIL-L- temperatur MOBILUBE HD 90 GP 80 W 90 GEAR OIL HD 80 SPIRAX Oil 80 W BP Hypogear 80
3.5 3.5 3.5 LOT CX ROTRA HP
2105D EP 90 -140 W 90 90 W 90

AGROLUBE MANTOS Degrees C -8 -15 -25 -35


Cooling Circuit 2.0 2.7 2.7 Antifreeze fluid in the foliowing percentages
% 20 30 40 50

ISO 8217 DMA,


Fuel tank 50 50 50 Decanted and filtered diesel fuel SB2869 Al or A2
(cetane N.: 45 min)

(1) Use only lubricants that comply with MF, FORD ESEM M 2 86 A and B, M-F 1135 specifications, with additives and anti-noise proper- ties. The use of different types
of oil, or mixing other types of oil into the oil supplied with the tractor can lead to increased noise.
SECTION100 - GENERAL INFORMATION

CONVENTIONAL UNITS OF MEASUREMENT

Units of measurement
(International system) Conversion: 1 N 1 kg 0.1019 kg 9.81
Force in (Newtons) =
N
Power in kW (kilowatts)
Torque in Nm (Newton meter) Conversion: 1 kW = 1.36 HP Other units of measurement
1 kW = 1.34 HP used:
Specific consumption in g/kWh (grams per 1 CV = 0.736 kW HP (Horsepower)
kilowatthour) 1 HP = 0.986 HP HP (Horsepower)
1 HP = 0.746 kW
1 HP 1.014 HP
=

Pressure in kPa (kilopascal) Conversion: 1 Nm = 0.1019 kgm


1 kgm = 9.81 Nm
1 kgm 10 Nm *
=

Conversion: 1 g/kWh = 0.736 g/HPh Other units of measurement


1 g/HPh 1.36 g/kWh used:
g/HPh (grams per horsepower
hour)
Conversion:
1 kg/cm2 = 1 Atm Other units of measurement
used:
1 kg/cm 2
= 98.1 kPa
kg/cm2 (kilogram/square cen-
1 kg/cm = 0.981 bar
2
timeter)
1 kg/cm2 = 1 bar * Atm (Technical atmosphere)
1 kg/cm2 = 14.22 psi psi (Pounds per square inch)
1 bar =
100 kPa
* For the sake of simplicity, the Nm and bar units
are converted according to ratios 10:1 and 1:1. 1 bar = 1.02 kg/cm2
1 bar = 14.51 psi
Conversion values for Imperial measurement 1 psi = 6.9 kPa
system 1 psi = 0.069 bar
0.1 mm = 3.937
1 psi mils= 0.0703 kg/cm2
1 mm 1 kPa inch= 0.145 psi
= 0.039
1 kPa = 0.0102 kg/cm2
1m = 3.281 ft
1 kPa = 0.01 bar
1 km = 0.621 miles
1 cm3 = 0.061 cu.in

1l = 1.759 pts (0.88 imp. qts)

1 bar = 14.5038 psi

1g = 0.035 oz. (0.564 dr)

1 kg = 2.205 lbs

1t = 1.102 short ton (0.9842 long ton)

0 C = 32 F

(In the case of temperature differences 1 C = 1.8 F)

0^
SECTION100 - GENERAL INFORMATION <L

STANDARD DRIVING TORQUE VALUES

Screws with metric threads


Maximum driving torque values for metric threads in kgm.

P/N3676163M1 Edition 07-2004 100-23


Class 8.8 screw Class 10.9 screw Class 12.9 screw
Diameter
x pitch d Cadmium Normal Galva- Cadmium Normal Galva- Cadmium
Norma Galva-
x p (mm) l plated nized plated nized plated
nized
0.193 0.173 0.15 0.234 0.21 0.187
3x5 0.153 0.137 0.122
4x0.7 0.316 0.284 0.252 0.438 0.394 0.35 0.53 0.477 0.424

0.49 0.87 0.78 0.69 1.03 0.93 0.82


5x0.8 0.612 0.55
1.48 1.33 1.18 1.78 1.60 1.42
6x1 1.06 0.95 0.85
2.00 3.54 3.18 2.83 4.24 3.02 3.39
8x1.25 2.51 2.25
3.73 3.35 2.98 4.47 4.03 3.57
8x1 2.65 2.38 2.12
4.08 7.19 6.47 5.75 8.63 7.76 6.90
10x1.5 5.11 4.60
4.27 7.51 6.75 6.00 9.02 8.11 7.21
10x1.25 5.34 4.81
12.14 10.92 9.71 14.59 13.13 11.67
12x1.75 8.65 7.78 6.02
12.95 11.66 10.36 15.61 14.05 12.48
12x1.25 9.24 8.32 7.39
19.38 17.44 15.50 23.26 20.93 18.60
14x2 13.77 12.39 11.01
20.61 18.55 16.48 24.69 22.20 19.75
14x1.5 14.59 13.13 11.67
29.38 26.44 23.50 35.30 31.77 28.24
16x2 20.91 18.82 16.72
16x1.5 21.83 19.65 17.46 30.81 27.73 24.64 36.93 33.24 29.54

40.61 36.55 32.48 48.77 43.69 39.00


18x2.5 28.87 25.98 23.09
44.28 39.85 35.42 53.06 47.75 42.44
18x1.5 31.42 28.28 25.13
57.34 51.61 45.87 68.77 61.89 56.00
20x2.5 40.81 36.73 32.64
20x2.5 40.81 36.73 32.64 57.34 51.61 45.87 68.77 61.89 56.00

20x1.5 43.97 39.58 35.17 61.93 55.74 49.54 74.28 66.25 59.42

22x2.5 54.23 48.85 43.42 76.32 68.69 61.05 91.53 82.37 73.22

22x1.5 58.26 54.43 46.60 81.93 73.74 65.54 98.36 88.53 78.68

24x3 70.51 63.45 56.40 99.08 89.17 79.26 119.33 107.44 95.50

24x2 74.53 67.13 59.67 105.10 94.59 84.08 125.51 112.95 100.40

27x3 100.36 92.75 82.44 144.89 130.40 115.91 173.46 156.12 138.76

27x2 109.18 98.26 87.34 153.06 137.75 122.44 183.67 165.30 140.97

30x3.5 130.79 125.81 111.03 198.93 177.24 157.54 235.71 212.14 183.60

30x2 151.02 135.91 120.81 212.24 191.02 169.79 254.08 228.67 203.26

100-24 P/N3676163M1 Edition07-2004


SECTION100 - GENERAL INFORMATION

Nuts with metric threads


Maximum driving torque values for metric threads in kgm.

Standard nuts Dropped nuts Standard nuts Dropped nuts


Diameter x Diameter x
galvanized galvanized galvanized galvanized
pitch d x p pitch d x p
(mm) MAT. 5S MAT. 8G MAT. 5S MAT. 8G (mm) MAT. 5S MAT. 8G MAT. 5S MAT. 8G

5x0.8 0.55 - 0.35 - 18x2.5 27.00 39.00 17.00 24.50

6x1 0.95 1.30 0.60 0.80 18x1.5 30.50 42.50 19.00 26.50
8x1.25 2.30 3.20 1.40 20x2.5 30.50 54.00 19.00 34.00
2.00

8x1 2.50 3.50 1.60 2.20 20x1.5 42.50 60.00 26.00 37.50
10x1.5 4.60 6.40 2.90 4.00 22x2.5 51.00 72.00 32.00 45.00

10x1.25 4.90 6.80 3.10 4.20 22x1.5 57.00 80.00 36.00 50.00

12x1.75 8.00 11.00 5.00 6.90 24x3 66.00 93.00 41.00 58.00

12x1.25 8.80 12.50 5.50 7.80 24x2 72.00 100.00 45.00 63.00

14x2 12.50 18.00 7.80 11.00 77x3 98.00 140.00 61.00 88.00

14x1.5 14.00 19.50 8.80 12.00 27x3 105.00 150.00 66.00 94.00

16x2 19.50 27.50 12.00 17.00 30x3.5 135.00 185.00 85.00 116.00

16x1.5 21.00 29.50 13.00 18.50 30x2 145.00 205.00 91.00 128.00

P/N3676163M1 Edition 07-2004 100-25


0^ SECTION 100 - GENERAL INFORMATION 2
SECTION 200

ENGINE
SECTION200 - ENGINE
Q
INDEX

Description Page

GENERAL FEATURES ................................................................................................................... 200-5

MAIN SPECIFICATIONS .............................................................................................................. 200-10

DRIVING TORQUES.................................................................................................................... 200-17

SPECIFIC EQUIPMENT................................................................................................................ 200-18

SECTIONS ............................................................................................................................... 200-19

LUBRICATION, COOLING AND FUELLING CIRCUIT DIAGRAMS ......................................................... 200-21

ENGINE TROUBLESHOOTING....................................................................................................... 200-24

ENGINE SPLITTING AND REMOUNTING......................................................................................... 200-32


Splitting......................................................................................................................... 200-32
Remounting.................................................................................................................... 200-35

COMPRESSION TEST.................................................................................................................. 200-36


Compression degree........................................................................................................ 200-36
Measuring procedure ...................................................................................................... 200-36

ENGINE - OVERHAUL.................................................................................................................. 200-39


Demounting.................................................................................................................... 200-39
Assembly of tappets and drive shaft with main bearing caps, bearings and bearing rings . . . 200-51 Assembly
of pistons complete with piston rings, pins, connecting rods, caps and bearings . . . 200-52
Assembly of timing, lubrication, starting, recharging, cooling and fuelling components.............. 200-54
Valve play adjustment...................................................................................................... 200-57
How to check the belt tension .......................................................................................... 200-58

INJECTOR NOZZLE AND INJECTION PRESSURE MEASURING AND MONITORING ................................ 200-59
Injection pressure measurement ...................................................................................... 200-59
Jet inspection.................................................................................................................. 200-60
Atomizer valve sliding test................................................................................................ 200-61
Identification number of the atomizer casing....................................................................... 200-61

INJECTION TIMING ADJUSTMENT AND MONITORING ..................................................................... 200-61

IDLING RATE ADJUSTMENT (MINIMUM AND MAXIMUM).................................................................. 200-63

HOW TO CHECK THE COOLING SYSTEM AND RADIATOR TO FIND LEAKS .......................................... 200-63

SENSOR INSPECTION ................................................................................................................ 200-64


Thermostat .................................................................................................................... 200-64
Thermal switch .............................................................................................................. 200-64
Hydraulic switch.............................................................................................................. 200-65

CYLINDER HEAD INSPECTIONS, MEASUREMENTS AND REPAIRS....................................................... 200-65


Warping and inspection of the combustion surfaces.............................................................. 200-65
Valve impression ............................................................................................................ 200-66
Valve housing width and angle ...................................................................................... 200-66
Valve housing interventionprocedure............................................................................... 200-67
Grinding and milling tool use procedure ............................................................................. 200-67
Valve housing removal ................................................................................................. 200-68
Valve housing insertion.................................................................................................. 200-68

200-2 P/N3676163M1 Edition07-2004


SECTION200 - ENGINE

Description Page
Valve stem wear and warping............................................................................................ 200-69
Valve stem and valve guide .............................................................................................. 200-69
Valve head thickness........................................................................................................ 200-69
Valve guide replacement .................................................................................................. 200-70
Valve stem seal................................................................................................................ 200-70
Valve spring inspection .................................................................................................... 200-71
Spring cap and cotter inspection........................................................................................ 200-71

CRANKCASE AND CYLINDER LINER INSPECTIONS, MEASUREMENTS AND REPAIRS............................. 200-72


Crankcase inspection........................................................................................................ 200-72
Measurement of cylinder liner bore and warping ................................................................. 200-73
Lapping ......................................................................................................................... 200-73

ROCKER ARM INSPECTIONS, MEASUREMENTS AND REPAIRS .......................................................... 200-75


Measurement of the outer diameter of the rocker arm pin and inner diameter of the rocker arm 20075
Tappet rod curve inspection, measurement of the outer diameter of the tappets and inspection
of the contacting surfaces ................................................................................................ 200-76
Other inspections ............................................................................................................ 200-76

PISTON AND PISTON RING INSPECTIONS, MEASUREMENTS AND REPAIRS........................................ 200-77


Piston inspection...............................................................................................................200-77
Measurement of the outer piston diameter ......................................................................... 200-77
Shape of the piston rings.................................................................................................. 200-78
Measurement of the groove width of the piston ring, the piston ring and the distance
between ends.................................................................................................................. 200-78
Piston ring assembly........................................................................................................ 200-80
Measurement of the outer diameter of the pin and relative hole ............................................ 200-81

CONNECTION ROD INSPECTIONS, MEASUREMENTS AND REPAIRS .................................................. 200-82


Visual inspection...............................................................................................................200-82
Twist and parallelism measurement ................................................................................... 200-82
Measurement of the bush and connecting rod pin play.......................................................... 200-83
Measure the play between the pin bush and the pin itself...................................................... 200-83
Checking the connecting rod pin bearing contact.................................................................. 200-84
Mounting the piston and connecting rod ............................................................................. 200-84
Connecting rod side play .................................................................................................. 200-85

CAMSHAFT INSPECTIONS, MEASUREMENTS AND REPAIRS ............................................................. 200-86


Camshaft float .................................................................................................................200-86
Visual inspection of the camshaft ...................................................................................... 200-86
Camshaft incurvation measurement ................................................................................... 200-87
Intake/exhaust cam height measurement ........................................................................... 200-87
Measurement of the play between the camshaft pins
and their relative bushes................................................................................................... 200-88

DRIVE SHAFT INSPECTIONS, MEASUREMENTS AND REPAIRS ......................................................... 200-88


Drive shaft float .............................................................................................................. 200-88
Checking the colour of the drive shaft................................................................................. 200-89
Bearing inspection........................................................................................................... 200-89
Drive shaft incurvation...................................................................................................... 200-89
Measurement of the connecting rod pin and main bearing ..................................................... 200-90
Precautions for bearing assembly....................................................................................... 200-91

GEAR INSPECTIONS, MEASUREMENTS AND REPAIRS ..................................................................... 200-92


Gear inspections....................................................... 200-92
SECTION200 - ENGINE
Play measurement.................................................... 200-92
Q
Description Page
Checking and measuring the intermediate gear shaft and the gear itself................................. 200-92
Gear train ...................................................................................................................... 200-93

OIL PUMP INSPECTIONS, MEASUREMENTS AND REPAIRS .............................................................. 200-94

P/N3676163M1 Edition 07-2004 2003


Play between the external rotor and pump casing................................................................ 200-94
Play between inner and outer rotor ................................................................................... 200-94
Float between the pump casing and the inner and outer rotor .............................................. 200-95
Play between the rotor shaft and housing hole ................................................................. 200-95
Miscellaneous ................................................................................................................. 200-95

YANMAR INJECTION PUMP ......................................................................................................... 200-96


How to bleed air from the fuel circuit.................................................................................. 200-96

INJECTION PUMP - OVERHAUL.................................................................................................... 200-97


Demounting.................................................................................................................... 200-97
Assembly....................................................................................................................... 200-102
Plunger inspection ..........................................................................................................200-108
Delivery valve inspection..................................................................................................200-108
Plunger guide, plunger cylinder inspection ....................................................................200-109
Camshaft and bearing inspection.......................................................................................200-109
Fuel regulating pinion and rack inspection ....................................................................200-109

REGULATOR UNIT - OVERHAUL...................................................................................................200-110


Demounting................................................................................................................... 200-110
Assembly....................................................................................................................... 200-116
Checking the centrifugal weights of the regulator ...............................................................200-121
Regulator sleeve inspection..............................................................................................200-121
Regulator lever shaft assembly inspection ....................................................................200-122
Spring inspection ........................................................................................................... 200-122
Checking the torque adjuster spring assembly ...................................................................200-123
Checking the torsion spring assembly................................................................................200-123

P/N3676163M1 Edition 07-2004 2003


SECTION200 - ENGINE

GENERAL FEATURES
GENERAL FEATURES MISTRAL AMERICA 40
SECTION200 - ENGINE
Engine

- Version/Position.............................................. 3TNE88 - ELAN

- Manufacturer................................................. Yanmar

- Cycle............................................................ diesel, four-stroke

- Injection....................................................... direct

- Number of cylinders in line.............................. 3

- Cylinder liners................................................ formed in the crankcase

- Bore............................................................. ............(mm)
88
- Piston stroke................................................. ............(mm) 90

- Total swept volume......................................... ............ (cc.) 1642

- Firing order................................................... 1-3-2

- Compression ratio.......................................... 18:1

- Power DIN 70020 (ISO 3046/1)........................ ........(HP/kW) 34/25 (37.5/27.5)

- Top rate on load............................................. ............(RPM)


2800
- Idling rate..................................................... ............(RPM) 2995

- Maximum torque............................................ ............ (Nm) 103

- Maximum torque rate...................................... ............(RPM)


1800
- Idling rate..................................................... ............(RPM)
1000
- Rotation direction........................................... Anti-clockwise (viewed from flywheel)

- Number of main bearings................................ 4


Recommended diesel fuel................................

ISO 8217 DMA, BS 2869 A1 or A2 (cetane N.:


45 min)
- Lubrication system......................................... Forced lubrication with trochoid pump

- Capacity of lubricating oil reservoir................... ..........(litres) 4.7

- Recommended lubricating oil........................... See section 100

- Cooling system.............................................. Coolant/Radiator

- Capacity of cooling fluid reservoir..................... .......... (litres) 2.0

- Cooling fan.................................................... Fan with 6 blades, 0 335 mm


- Regulator......................................................
Centrifugal mechanical type (all speeds)

- Ignition system.............................................. Electrical

-Q

2006 P/N3676163M1 Edition07-2004


(continued)
GENERAL FEATURES MISTRAL AMERICA 50
45
SECTION200 - ENGINE
Engine

- Version/Position..............................................
Version/Position............................................. 4TNE84 - ELAN
4TNE88

- Manufacturer.................................................
Manufacturer................................................ Yanmar

- Cycle............................................................
Cycle........................................................... diesel, diesel, four-stroke
four-stroke water cooled

- Injection....................................................... direct
- Injection....................................................... direct
- Number of cylinders in line.............................. 4
- Number of cylinders in line.............................. 4
- Cylinder liners............................................... formed in the crankcase
- Cylinder liners................................................ formed in the crankcase
- Bore............................................................ ..........(mm) 84
- Bore............................................................. ............(mm) 88
- Piston stroke................................................. ..........(mm) 90
- Piston stroke................................................. ............(mm) 90
- Total swept volume........................................ ............(cc.) 1995
- Total swept volume......................................... ............ (cc.) 2189
- Firing order .................................................. 1-3-4-2
- Firing order................................................... 1-3-4-2
- Compression ratio.......................................... 18:1
- Compression ratio.......................................... 18:1
- Power DIN 70020 (ISO 3046/1)....................... ____(HP/kW) 40/29.4 (44/32)
- Power DIN 70020 (ISO 3046/1)........................ ........(HP/kW) 45/33 (49.5/36.5)
- Top rate on load............................................. ..........(RPM) 2800
- Top rate on load............................................. ............(RPM) 2800
- Idling rate.................................................... ..........(RPM) 2995
- Idling rate..................................................... ............(RPM) 3025
- Maximum torque........................................... ............(Nm) 120
- Maximum torque............................................ ............ (Nm) 135.8
- Maximum torque rate..................................... ..........(RPM) 1600
- Maximum torque rate...................................... ............(RPM) 1600
- Idling rate.................................................... ..........(RPM) 1000
- Idling rate..................................................... ............(RPM) 1000
- Rotation direction.......................................... Anti-clockwise (viewed from flywheel)
- Rotation direction........................................... Anti-clockwise (viewed from flywheel)
- Number of main bearings................................ 5
- Number of main bearings................................ 5
Recommended diesel fuel............................... ISO 8217 DMA, BS 2869 A1 or A2 (cetane N.:
Recommended diesel fuel................................ ISO 8217 DMA, BS 452869 A1 or A2 (cetane N.:
min)
45 min)

- Lubrication system......................................... Forced lubrication with trochoid pump


- Lubrication system......................................... Forced lubrication with trochoid pump
- Capacity of lubricating oil reservoir................... ..........(litres) 5.8
- Capacity of lubricating oil reservoir................... ..........(liters) 5.8
- Recommended lubricating oil........................... See section 100
- Recommended lubricating oil........................... See section 100
- Cooling system.............................................. Coolant/Radiator
- Cooling system.............................................. Coolant/Radiator
- Capacity of cooling fluid reservoir..................... ..........(litres) 2.7
- Capacity of cooling fluid reservoir..................... ..........(liters) 2.7
- Cooling fan................................................... Fan with 6 blades, 0 370 mm
- Cooling fan.................................................... Fan with 6 blades, 0 370 mm
- Regulator..................................................... Centrifugal mechanical type (all speeds)
- Regulator...................................................... Centrifugal mechanical type (all speeds)

- Ignition system............................................. Electrical


- Ignition system.............................................. Electrical

2006 P/N3676163M1 Edition07-2004


(continued)

MISTRAL AMERICA
GENERAL FEATURES
40 45 50

Timing system

Type................................................................ With overhead valves controlled by


tappets
Intake:

- start: before T.D.C.......................................


10 - 20

- end: after B.D.C.......................................... 40 - 50

Exhaust:
- start: before T.D.C.......................................
51 - 61
- end: after B.D.C..........................................
13 - 23
Gap between valves and tappets with engine cold:

- intake........................................................

- exhaust .....................................................
(mm) 0.15 - 0.25
For further technical data about the timing system
(mm) 0.15 - 0.25
Fuel system

Type................................................................

Air cleaning......................................................
Aspirated

5" dry filter with two elements removable


Fuel pump ....................................................... for maintenance

Fuel cleaning.................................................... Yanmar

Control............................................................. Paper filter on injection pump delivery

Injection pump ................................................. By eccentric

Speed governor, at all rates, built into the pump. . Yanmar

Automatic lead variator, built into the pump.......... Yanmar

Cold starting device........................................... Yanmar

For further technical data about the fuel system Thermostarter

- Fixed lead...................................................

- Firing order ................................................ o


16
Injectors..........................................................
1-3-2 1-3-4-2
- Pressure setting..........................................
Yanmar

(bar) 216 - 226 196 - 206


(continued)
MAIN SPECIFICATIONS
MAIN SPECIFICATIONS Nominal value MISTRAL AMERICA
Value at limit of
GENERAL FEATURES
40wear 45 50
Cylinder head
Cylinder head combustion surface warp........................ . . . . (mm) < 0.05 0.15
Lubrication
Valve housing angle
Type.........................................................................................
- Intake................................................................... 120 -

- Exhaust................................................................. 90
Oil cleaning............................................................................... forced,
- by means of pump

Valve housing width gauze filter (on pump intake)


- Intake................................................................... . . . . (mm) 1.07 - 1.24 1.74
cartridge filter (on engine delivery)
- Exhaust.................................................................
Oil pressure with engine at top power . . rate.............................(bar)
. . (mm) 1.24 - 1.45 1.94
3-4
Intake valve Recommended oil.......................................................................
See section 100
- Outer diameter of valve stem.................................... . . . . (mm) 7.955 - 7.975 7.9
Cooling ith forced circu
- Inner diameter of valve guide................................... . . . . (mm) 8.010 - 8.025 8.1 mp operated b
Type......................................................................................... water, w ie timing syste
- Assembly play between valve stem and guide . . . . . . . . (mm) 0.035 - 0.070 0.2pu
centrifugal
lation by / the
Exhaust valve t
2.7 gears of m
- Outer diameter of valve stem.................................... . . . . (mm) 7.955 - 7.970 7.9
Capacity of cooling fluid reservoir.............................................(l) 2.0 ied fan, 0 373
2.7 mm
- Inner diameter of valve guide................................... . . . . (mm) 8.015 - 8.030 8.1
Cooling fan................................................................................ Blac 370
- Assembly play between valve stem and guide . . . . . . . . (mm) 0.045 - 0.075 0.2 x6
Fan diameter and number of blades......................................(mm)
Valve guide projection................................................ . . . . (mm) 15 335 x 6- See section

Depth of valve impression


Recommended fluid.................................................................... 10C
- Intake valve........................................................... . . . . (mm) 0.306 - 0.506 1.0

- Exhaust valve......................................................... . . . . (mm) 0.3 - 0.5

Valve head thickness

- Intake valve........................................................... . . . . (mm) 1.244 - 1.444 0.5

- Exhaust valve......................................................... . . . . (mm) 1.35 - 1.55

Intake valve timing

- Open b. TDC .......................................................... 10 - 20 -

- Closed a. BDC ........................................................ 40 - 50

Exhaust valve timing


Nominal value Value at limit of
(mm) wear (mm)
- Open b. BDC ......................................................... 51 - 61
- Closed a. TDC......................................................... 13 - 23
Cylinder block

Bore
Valve spring
- Free length............................................................. . . . . (mm) 42
- Mod. MISTRAL AMERICA 45....................................................... 84.000 - 84.030
84.20
- Slant..................................................................... -
- Mod. MISTRAL AMERICA 40 and 50............................................ 88.0001.1
- 88.030
88.20
- Tension (when compressed -
Bore -1Mark
mm Lin length)............... ........(kg) 2.36 (variable
pitch)/3.101
- Mod. MISTRAL AMERICA 45....................................................... 84.020 - 84.030
Intake and exhaust valve play..................................... . . . . (mm) 0.15 - 0.25 - 84.20
SECTION200 - ENGINE

- Mod. MISTRAL AMERICA 40 and 50............................................ 88.020 - 88.030 88.20

Bore - Mark M

- Mod. MISTRAL AMERICA 45....................................................... 84.010 - 84.020 84.20

- Mod. MISTRAL AMERICA 40 and 50............................................ 88.010 - 88.020 88.20

Bore - Mark S

- Mod. MISTRAL AMERICA 45....................................................... 84.000 - 84.010 84,20


- Mod. MISTRAL AMERICA 40 and 50............................................ 88.000 - 88.010 88.20

Cylinder roundness
- Mod. MISTRAL AMERICA 45....................................................... 0.00 - 0.01 0.03

- Mod. MISTRAL AMERICA 40 and 50............................................ 0.00 - 0.01 0.03

Cylindricity
- Mod. MISTRAL AMERICA 45....................................................... 0.00 - 0.01 0.03

- Mod. MISTRAL AMERICA 40 and 50............................................ 0.00 - 0.01 0.03


(continued)

Nominal value Value at limit of


MAIN SPECIFICATIONS
(mm) wear (mm)
Rocker arms

Intake and exhaust valve rocker arms

- Outer diameter of rocker arm pin............................... 15.966 - 15.984 15.95

- Inner diameter of rocker arm bush............................. 16.000 - 16.020 16.09

- Assembly play between pin and bush.......................... 0.016 - 0.054 0.14

Rocker arm rod incurvation.......................................... < 0.03 -

Tappets
- Outer diameter of tappet stem................................... . . . . (mm) 11.975 - 11.990 84.20

- Inner diameter of tappet guide hole............................ . . . . (mm) 12.000 - 12.018 88.20

- Assembly play between tappet guide and stem . . . . . . . . (mm) 0.010 - 0.043 0.12
(continued)
SECTION200 - ENGINE -Q
Nominal value Limit value of wear
MAIN SPECIFICATIONS (mm) (mm)
Pistons

Outer diameter of piston


- Mod. MISTRAL AMERICA 45...................................................... 83.945 - 83.975 83.90

- Mod. MISTRAL AMERICA 40 and 50........................................... 87.945 - 87.975 87.90

Outer diameter of piston - Mark L


- Mod. MISTRAL AMERICA 45...................................................... 83.965 - 83.975 83.90

- Mod. MISTRAL AMERICA 40 and 50........................................... 87.965 - 87.975 87.90

Outer diameter of piston - Mark ML


- Mod. MISTRAL AMERICA 45...................................................... 83.960 - 83.965 83.90

- Mod. MISTRAL AMERICA 40 and 50........................................... 87.960 - 87.965 87.90

Outer diameter of piston - Mark MS


- Mod. MISTRAL AMERICA 45...................................................... 83.955 - 83.960 83.90

- Mod. MISTRAL AMERICA 40 and 50........................................... 87.955 - 87.960 87.90

Outer diameter of piston - Mark S


- Mod. MISTRAL AMERICA 45...................................................... 83.945 - 83.955 83.90

- Mod. MISTRAL AMERICA 40 and 50........................................... 87.945 - 87.955 87.90

Minimum play between piston and cylinder


- Mod. MISTRAL AMERICA 45...................................................... 0.040 - 0.070 -

- Mod. MISTRAL AMERICA 40 and 50........................................... 0.040 - 0.070 -

Upper play
- Mod. MISTRAL AMERICA 45...................................................... 0.660 - 0.780 -

- Mod. MISTRAL AMERICA 40 and 50........................................... 0.660 - 0.780 -

Piston and pin

- Outer diameter of pin


- Mod. MISTRAL AMERICA 45................................................ 25.987 - 26.000 25.90

- Mod. MISTRAL AMERICA 40 and 50...................................... 25.987 - 26.000 25.90

- Pin hole diameter

- Mod. MISTRAL AMERICA 45................................................ 26.000 - 26.009 26.02

- Mod. MISTRAL AMERICA 40 and 50...................................... 26.000 - 26.009 26.02

- Assembly play between pin and hole


- Mod. MISTRAL AMERICA 45................................................ 0.000 - 0.022 0.12

- Mod. MISTRAL AMERICA 40 and 50...................................... 0.000 - 0.022 0.12


(continued)
MAIN SPECIFICATIONS Nominal value Value at limit of
SECTION200 - ENGINE
(mm) wear (mm)

Piston rings

Upper ring

- Width of ring groove

- Mod. MISTRAL AMERICA 45................................................. 2.065 - 2.080 -

- Mod. MISTRAL AMERICA 40 and 50...................................... 2.060 - 2.075 -

- Ring width

- Mod. MISTRAL AMERICA 45................................................. 1.970 - 1.990 -

- Mod. MISTRAL AMERICA 40 and 50...................................... 1.970 - 1.990 -

- Minimum side play

- Mod. MISTRAL AMERICA 45................................................. 0.075 - 0.110 -

- Mod. MISTRAL AMERICA 40 and 50...................................... 0.070 - 0.105 -

- Gap between ends

- Mod. MISTRAL AMERICA 45................................................. 0.200 - 0.400 1.5

- Mod. MISTRAL AMERICA 40 and 50...................................... 0.200 - 0.400 1.5

2nd piston ring

- Width of ring groove

- Mod. MISTRAL AMERICA 45................................................. 2.035 - 2.050 -

- Mod. MISTRAL AMERICA 40 and 50...................................... 2.025 - 2.040 -

- Ring width

- Mod. MISTRAL AMERICA 45................................................. 1.970 - 1.990 -

- Mod. MISTRAL AMERICA 40 and 50...................................... 1.970 - 1.990 -

- Minimum side play

- Mod. MISTRAL AMERICA 45................................................. 0.045 - 0.080 -

- Mod. MISTRAL AMERICA 40 and 50...................................... 0.035 - 0.070 -

- Gap between ends

- Mod. MISTRAL AMERICA 45................................................. 0.200 - 0.400 1.5

- Mod. MISTRAL AMERICA 40 and 50...................................... 0.200 - 0.400 1.5


(continued)
SECTION200 - ENGINE -Q
Nominal value Value at limit of
MAIN SPECIFICATIONS (mm) wear (mm)

Piston rings
Oil scraper ring

- Width of ring groove

- Mod. MISTRAL AMERICA 45................................................ 4.015 - 4.030 -

- Mod. MISTRAL AMERICA 40 and 50...................................... 4.015 - 4.030 -

- - Ring width

- Mod. MISTRAL AMERICA 45................................................ 3.970 - 3.990 -

- Mod. MISTRAL AMERICA 40 and 50...................................... 3.970 - 3.990 -

- Minimum side play DRIVING TORQUES


PARTS TO TORQUE Thread Driving torque
- Mod. MISTRAL AMERICA 45................................................ 0.025 - 0.060 -
Nm
- Mod. MISTRAL AMERICA 40 and 50...................................... 0.025 - 0.060 - kgm
Cylinder head fixing bolts C1)..................................................... M10 x 1.25 85.3 - 91.2
- Gap between ends 8.7 - 9.3

Connecting rod cap fixing bolts C ).............................................


- Mod. MISTRAL AMERICA 45................................................
1
0.200 - 0.450 M9
1.5x 1.0 44.1 - 54.0
4.5 - 5.5
- Mod. MISTRAL AMERICA 40 and 50......................................
Flywheel 0.200 - 0.400
fixing bolts C1)............................................................ 1.5 x 1.25
M10 83.4 - 88.3
8.5 - 9.0

Main bearing cap fixing bolts C )................................................


1
M12 x 1.5 96.1 - 100.1
MAIN SPECIFICATIONS Nominal value Value at limit of 9.8 - 10.2
(mm) wear (mm)
Drive shaft V-pulley fixing bolts C ).............................................
1
M14 x 1.5 112.8 - 122.6
Connecting rods 11.5 - 12.5

Connecting rod pivot side Injector nuts C2)...................................................................... M6 x 1.0 6.9 - 8.8 0.7 - 0.9
MAIN SPECIFICATIONS Nominal value
(mm) Value at limit of
- Inner diameter of connecting rod pivot bush...............................
Automatic 51.000 - 51.010
lead fixing nuts C2).................................................... -
M12 x 1.75 58.9 - 68.7 wear (mm)
6.0 - 7.0
Drive shaft
- Thickness of connecting rod pivot bearing................................... 1.492 - 1.500 -
Bearing nut nut centrifugal weights of governor C2)...................... M12 x 1.25 44.1 - 49.1 4.5 - 5.0
Main journal
- Outer diameter of connecting rod pivot...................................... 47.952 - 47.962 47.91
Fixing
- Outernut of high of
diameter pressure diesel fuel pipe sleeve C 2)....................
main journal.................................................. M1253.952
x 1.5 - 53.962
29.4 - 34.3 3.0 - 3.5
- Assembly play between pivot and bearing.................................. 0.038 - 0.058 0.16 53.91
- Thickness
Hex of main
bolts C7T) bearing.........................................................
and nut C2) C3)................................................... M61.995
x 1 - 2.000
9.8 - 11.8 1.0
Pin side
(continued) - - 1.2
MAIN SPECIFICATIONS SECTION200 - ENGINE
Nominal value Value at0.038
- Assembly play between main journal and bush............................ limit-of
0.068
- Inner diameter of pin bush....................................................... 26.025 - 26.038 M8 x 1.25
26.10 22.6 - 28.4 2.3 - 2.9
0.15
(mm) wear (mm)
Incurvation............................................................................... < 0.02 (continued)
Camshaft
- Outer diameter of pin.............................................................. 25.987 - 26.000 25.90x 1.5
M10 44.1 - 54.0 - - 5.5
4.5
MAIN SPECIFICATIONS Nominal value
Gear side play between pin and bush.........................................
- Assembly 0.025 - 0.051 0.2 x 1.75
M12 78.5 - 98.1 8.0 - 10.0
MAIN SPECIFICATIONS Nominal value
Engine cooling circuit MAIN SPECIFICATIONS
- Outer diameter of camshaft main journal.................................... 44.925 - 44.950 Nominal
44.85 value
Twist and parallelism .................................................................
PT plugs lubrication < 0.03 every
C2)............................................................................ 0.08
1/8" 9.8 1.0
Engine circuit 100 mm .......(l/min) (mm)
Coolant pump delivery volume
- Assembly play between journal and housing................................ 0.040 - 0.130 - 70
25.0 (at 3600 RPM) 8.0 (at 800 RPM)
Float
(at 3220 - 3280 RPM)...................................... 1/4" 19.6 2.0
Lubricating oil pump delivery volume
Drive shaft float......................................................................... 3.0 - 4.0 0.4 - 0.6
0.090 - 0.271
Intermediate Thermostatic valve opening temperature 3/8" 29.4 3.0
-Camshaft
- Outer diameter of camshaft main Operation at high speed.......................................(l/min)
journal.................................... 44.910 - 44.935
float........................................................................... 44.850.05 - 0.25
- Opening temperature..................................... .........(C) 1/2" 69.5
58.9- 72.5 6.0
-Connecting
- Assembly play between journal Operation
and at low speed........................................(l/min)
housing................................ 0.065 - 0.115
rod float................................................................... - 0.2 - 0.4
- Liftjoining
Pipe height...................................................... ....... (mm)
bolts C2)................................................................ M8 >12.8
8.0 -(> 85 C) 1.3 - 1.7
16.7
Flywheel side Pressure monitoring
Intermediate valve opening pressure...............(bar)
gear float............................................................... 0.1 - 0.3
Thermal switch activating temperature M12 24.5 - 34.3 2.5 - 3.5
- Outer diameter of camshaft main journal....................................
Operating
Float pressure
for injection pump,of lubricating
intermediate oil 44.925
pressure
gear, camshaft - 44.950
switch.
and drive .(bar)
shaft 44.850.07 - 0.15
- ON................................................................. .........(C) M14 107
39.2 - 113
- 49.1 4.0 - 5.0
gears........................................................................................
- Assembly play between journal and housing................................ 0.050 - 0.100 -
-Lubricating
OFF................................................................ ....... (mm)
oil pump float............................................................ M16 49.1>
0.11 - 0.19 100
- 54.0 5.0 - 5.5
Incurvation............................................................................... < 0.02 0.05
SECTION200 - ENGINE

C1) Parts spread with lubricating oil.

(2) Parts not spread with lubricating oil.

(3) a. When aluminium parts are mounted, tighten the bolts to 80% of the driving torque value given in
the table.
b. 4T bolts and check nuts must be tightened to 60% of the torque value given in the table.
SPECIFIC EQUIPMENT
Code Description

001 MT MIS Dummy injector


002 MT MIS Compression test equipment

003 MT MIS Valve spring compression tool

004 MT MIS Tool to mount the piston rings

005 MT MIS Tool to mount the piston complete with liners

006 MT MIS Valve guide puller

007 MT MIS Valve guide seating tool

008 MT MIS Puller to remove the eccentric weights of the injector regulator - MISTRAL
AMERICA 40

009 MT MIS Puller to remove the eccentric weights from the injection regulator - MISTRAL
AMERICA 45/50

010 MT MIS Bracket to support the injection pump tappets

011 MT MIS Tool to seat the injection pump plunger

012 MT MIS Injection pump float tool


SECTION200 - ENGINE

SECTIONS

Longitudinal section of engine (mod. MISTRAL AMERICA 40)


1

1. Drive
shaft
2. Cams
haft
SECTION200 - ENGINE

2LA0002

2
Cross-section of engine (mod. MISTRAL AMERICA 40)
1. Injection pump 6. Piston
2. Injector 7. Starter motor
3. Tappet cover 8. Connecting rod
4. Rocker arms 9. Lubricating oil suction pipe
5. Cylinder head
SECTION200 - ENGINE

LUBRICATION, COOLING AND FUELLING CIRCUIT DIAGRAMS

2LA0003

3
Engine lubrication circuit diagram.

1. Heat exchanger (on request) 10. Rocker arms


2. Oil filter (with bypass valve) 11. Rocker arm pin
3. Pressure governor valve 12. Camshaft bearing
4. Injection pump 13. Intermediate gear pin
5. Pressure switch 14. Oil sump
6. Main cylinder block duct 15. Oil intake pipe (with gauze filter)
7. Main bearing 16. Oil pump
8. Big end bearing 17. Safety valve
9. Tappets/cam surfaces
SECTION200 - ENGINE

2LA0004

4
Engine cooling circuit diagram.
1. Cylinder head 5. Radiator
2. By-pass 6. Water pump
3. Thermostat 7. Heat exchanger for oil (on request)
4. Secondary tank 8. Cylinder block
SECTION200 - ENGINE

5
Engine fuelling circuit diagram.
1. Injector 6. From fuel tank
2. High pressure injection tube 7. Fuel pump
3. Fuel return tube 8. Fuel filter
4. Injection pump 9. Breather pipe
5. Oil separator (on request) 10. To fuel tank

0^ <
SECTION200 - ENGINE

ENGINE TROUBLESHOOTING
Possible causes Remedies
Faults Possible causes Remedies
SECTION200 - ENGINE SECTION200
SECTION200 --ENGINE
ENGINE

0^
Faults Possible causes Remedies

<
The engine starts but then SECTION200
Idling rate causes
too low. - ENGINE Possible
Adjust causes
idling rate. Remedies
The engine fails to start Faults
1. Battery slightly low. Possible Remedies
Check, recharge the battery and
11.
Noisy4.Injection
piston pump
pins owingwith tomaximum
excessive screw Adjust
Use
play Fit the maximum
a suitable
larger screw.
lubricating
piston true oil.
stops
Excessive vibration in engine. Irregularreplace
1. Intake/exhaust fuel
valves itjammed.
supply if necessary.Too
to injec- much
Replace.
tion lead
Lubricating
pump on injection
Check oil
the flowpump.
with rates wrong
on the Correctly
test bench. time the pin,
injection the
pumppiston
on
badly
in the adjusted.
piston
spec- ifications.bosses and big end pin. bosses
engine. and big end bushes. Replace
2. Connections to battery termi- nals
2. Spring rings Clean,
jammed inspect, tighten
or dam- the nuts
Replace.
Bushes free and,
in the if big end housing. the bushes.
corroded or slack. aged. Impurities necessary, 12.
replace Oil5. Drop
oozes
any inexcessively
Leaks engine
through from compression
the intake valve
lubricating duecircuit
to: Overhaul
guide Repair/replace.
Replace the the cylinder
damagedhead. parts or over-
or water accumu- lated in the Detach the pipes, the injection pump
corroded terminals and nuts. - jammed
owing to piston
worn valverings; stems
pipes. and thoroughly clean them. If or guides. haul the engine if necessary.
3. Big end pin fuel pipes. Repair or replace.
and bearings jammed. 10. Ticking
- worndue to noisy
cylinder liners;timing system. Make sure that there are no broken
necessary, clean and dry the fuel tank.
6.
- worn Lubricating
or badly adjustedoil filtervalves. clogged. springs,Replace.that the play between stems
The engine fails to reach operating and Replace the thermostat.
guides, tappets and housings is
3. Circuit open. 4. Big end bearings Close the circuit.
and main Measure 7. Worn or replace.
temperature (thermostat pressure monitoring
damaged). Clean, adjust
not excessive. Adjust or replace.
the play between
Fuel filters clogged Replace integral filter cartridges.
Faults bearings worn. Possible causes valve. Remedies the valves and rocker arms.
4. Intake/exhaust valve Adjust valve play.13. Big end bearing and main bear- ing Measure or replace.
5. play
Big incorrect.
end fixing bolts
Abnormal playslackened.
between valves 8. and
Tighten to theAdjust
rocker
Insufficient prescribed
oilplay between
torque value.
capacity. valvesTop andup
Mount rocker
to maximum oil level.
correctly.
Injection pump with incorrect 7. worn. Piston
setting. Adjust rings the injection incorrectly
pump on the test
arms.
Abnormal black or dark grey Maximum flow arms.
rate of injection Adjust the injection pump on the
5. Intake/exhaust valve seized. Replace. mounted/positioned. bench in compliance withAdjust
the settings
Temperature increase at 1. Intake/exhaust valve play valve play.
6.
smoke from
Valves
Injection the engine.
seized,
pump burnt or cracked.
regulator 14. Reduced
dam- Repair
pump too cooling
or replace.
high.Replaceeffect from
the valves. radiator. Defective thermostat (check/ replace).
exhaust. incorrect. in the table. test
Adjustbenchvalve play in compliance
and timing. with the
Intake/exhaust valve timing incorrect. Adjust fan belt tension.
aged.
6. Piston rings seized or broken. Replace piston ring. settings in the table.
Air
Air filter
in theclogged. Clean the
fuel circuit.
15. 2. Loss
Insufficient ofCheck
cooling the unit
compression
fluid. pipes, andunions,
replace
from Lap the
fuel valvefilter
pump, housing.
7. Excessive injection pump lead. The Checkinjectionand adjust.
pump
element is delayed
if necessary. Check to time
too much Correctly makethesure that no
injection pump water
on
7. Cylinder and piston rings worn. Lap and use largerDiesel size parts. valve filters
housings. and injection Use
pump suitable
for air. diesel fuel.
or fuel the with the wrong
automatic lead specifications.
variator is the leaks fromorthe
engine check cooling system lead
the automatic and
Excessive fuel consumption. 1. Loss 10.ofCylinder
compression from valve Lap
liners cracked
valve housing. Lastly, bleed the circuit.
Replace.
damaged. clean it.
housing. 3. Spring rings seized or variator.
Replace piston rings.
8. Big end pins and bearings seized. Repair or replace. broken. Replace the damaged parts.
10. Water in injection
the belt
fuelling circuit. Check and repair.
11.Injection
Damaged pump controls
cylinder headdam- Too
16.
seal. aged.
much
Wrong fan pump
tension.
Replace lead.
the seal. Adjust
Correctly fantimebelt tension.
the injection pump on
2. Radiator cools too much. 4. Reduced
Thermostat defective.
cooling effect from engine. Check/replace thermostat.
The engine failsDemount
9. Foreign body in combustion to stop. and repair Stopping the electromagnet
radiator.chamber. damaged. Replace the electromagnet.
Check/adjust
Check/replace. fan belt slip.
17. Thermostat worn.
Replace
chamber.
3. Excessive
12.Damagedinjection
Piston rings
Remove
pump
jammed
cylinder the
delay
head orseal.
foreign
Check
damaged.
body.
and adjust. Replace the the piston
seal. rings.
Injectors partially and/or totally clogged Clean, overhaul and correctly cali-
5. Insufficient cooling fluid. Checkthe for injectors;
leaks from the system/
Excessive consumption of Abnormal
1. knocking
Piston rings seized in or engine.
broken. 1. Injectors Replace.
or with incorrectpartially set- clogged ting.or damaged. brate Clean, overhaul andreplace them
correctly if
cali-
10. Intake/exhaust valve 10.
Oscillation,
timing Piston ring
instabilityseized
Adjust the in or broken.
valvethe Speed
play and checkReplace
governor, attheall rates,piston ring.
damaged. Overhaul the injection pump and
repair.
lubricating Coolant
oil. temperature too 2. low.
Cylinder
1. rate.and piston
The timing
radiator'srings worn. Lap and use Replace
larger size the thermostat.
parts. necessary.
brate the injectors.
incorrect. rotation of thecooling capacity
intake/exhaust is
valves. adjust it on the test bench in com-
11. Cylinder
excessive andowing
pistontorings incorrect 6.
worn.
Air filter Fan
operation beltLap
clogged. tension
and use incorrect.
larger size parts. Adjust
pliance
Clean tension.
with
the the settings
unit and in thethe
table.
2. Impurities in the fuel pipes. Clean the pipes and replace
replace any filter
that
11. Incorrect timing 3. Incorrect
of injection ofalignment
pump theCorrectly of piston
thermostat. time the Correct gap
ringinjection pump alignment.
on element if necessary.
(continued)
gap. Repair or replace. are excessively dented. Clean the
on engine. 12. Big endengine.pin and bearings seized.
Low engine power and irregu- lar Incorrect timing of injection pump on Correctly
Drop in engine compression due to: time the injection
injection pump pump
on if necessary.
Replace the damaged parts or over-
12. Impurities or water
operation. 4. accumu-
Invertedlatedassembly of piston rings Mount correctly.
engine. engine.
- jammed piston rings; haul the engine if necessary.
in the fuel pipes. Detach the pipes, 3. theIncorrect
injection timingpump
Correct
of injection pump on Correctly time the injection pump on
gap alignment.
- when13. idling
Incorrect alignment of piston Piston rings
ring
- worn gap. seized
cylinder or broken.
liners; Replace the piston rings.
Automatic andleadthoroughly clean
variator in injectionengine.pump them.Overhaul If the injection engine. pump and
5. Impurities in combustion
necessary, clean -dry worn
cham-and Demount the fuel or
andbadly
remove
tank. adjusted valves.
the impuri-
damaged. adjust it on the test bench in orcom-
ber. 4.Bigties.
end pins
The engine and shaft
bearings knocksseized.owing to Repair replace.
Grind the drive shaft pins; fit larger
The engine overheats. Centrifugal pump of engine cooling pliance with the settings in the table.
excessive play on one or more main or bearings andif bearing rings.
circuit Overhaul the pump and replace it
13. No fuel in tank 6. Intake/exhaust Fillvalve
inefficient. tank.guide Measure or replace. necessary.
big end
Injection bearings,
pipes damaged. or too much play in Measure or replace.
worn. Worn timing system pin. Bigthe end bearings and main bearings worn. Check the condition of the pipes and
sup- ports. Overhaul thethe injection replace
pump them and if necessary.
Thermostat Check and, if necessary, replaceReplace
inefficient. the thermostat.
14. No fuel supplied 7.to injection pump
Lubricating oilfuel with wrong spec- Use suitable lubricating
adjust it oil.
on the test bench in com-
pump.
Radiator partially inefficient.
ifications. Diesel
Drivefuel
5.Injection with
pump
shaft pliance
the
Remove wrong
regulator
unbalanced. with
any the settings
specifications.
damaged.scaling inUse
thesuitable
Repair
by washing. or
table.
Check diesel fuel.
replace.
15. Air in the fuel circuit. Check shaft alignment and balanc- ing.
and repair any leaks from the tubes.
8. Leaks from lubricatingCheck the oil pipes.
pipes, unions,Repair/replace.
fuel pump, Replace the shaft if necessary.
filters and injection
Water
Engine pump
in the
used for
fuelling
at air.
high circuit.
tempera- the injection Clean
tures and Use a higher
andand powered engine.
repair.
Water in the lubricating oil. 1. Damaged Irregular fuel supply to injection
cylinder 6. Flywheel
Replace.pump fixingOverhaul
bolts slackened. pump
Replace the slackened bolts and
Lastly, head
bleed housing
the circuit. altitudes. Thoroughly wash.
Scaling in the places where coolant adjust it on the test bench in com-
- whenseal.operating Intake/exhaust valves seized. tighten all bolts to the prescribed
Replace.
16. Starter motor damaged. passes Repair or replace
through the 10. theExhaust
cylinder starterhead motor. pliance with the settings inClean
andclogged. the table.
pipe torquepipe.value.
2. Cylinder liners cracked
crankcase. Replace.
Big end pins and bearings seized. Repair or replace.
17. Thermostarter inefficient.
Grey smoke tending Checktowards
or replacea7. the
The thermostarter.
Axes injection pump isrods
of connecting delayed not parallel. Correctly
Straightentime thethe injection rods,
connecting pump check
Fuel in the lubricating oil. 1. Intake/exhaust
Speed valves seized.
governor, Replace. Check and adjust the belt tension.
The belt that at all rates,
controls thedamaged.
centrifugal Overhaul the injection
the
pump and
parallelism
whitish, grey-blue or blue col- too much or the adjustautomatic
it on lead the test bench on the in engine
com- or check the auto-and, if
of the axes
2. Piston ringspump and or
seized fanbroken.
is too slack. Big Replace.
end bearings and main bearings worn. Measure
necessary, or replace
replace.the connecting rods
our. variator is damaged. pliance with the settings inmatic lead variator.
the table.
themselves.
3. Cylinder and piston rings worn. Lap and use larger
Injectors clogged or defective. size parts. Clean, overhaul and correctly cali-
8.Injection
Piston knocking due
pump regulator damaged.to abnormal wear. Repair
Ream the
brate or replace.
cylinder
injectors; liners and fit
replace larger
them if
Lubricating oil pressure too 1. Big end bearings
Injectors and main
partially clogged or Measure/replace.
damaged. Top up the
Clean, overhaullevel inand the expansion
correctly tank cali-
necessary.
pistons.
low. bearingsCooling
worn.fluid (quantity insuffi- cient). using the injectors.
brate recommended fluid.
(continued) Water in the fuelling circuit.
Oil oozes from the piston rings owing to Replace Clean andthe repair.
damaged parts or over-
2. Big end bolts slackened.
Impurities
Incorrect or water
engine accumu-Tighten
timing. lated inbolts. the Detach
Check the
and pipes, the
correctly timeinjection
the engine.pump
jammed rings or worn liners. haul the engine if necessary.
(continued) fuel pipes. and thoroughly clean them. If
(continued) 3. Cylinder liner cracked Replace.
necessary, clean and dry the fuel tank.
(continued)
(continued)

Fuel pump damaged. Replace fuel pump.

Air filter clogged. Clean the unit and replace the filter
element if necessary.
Adjust rod length.
10. Length of rod between acceler- ator and
injection pump badly regulated.

(continued)
ENGINE SPLITTING AND REMOUNTING

WARNING
Lift and handle all heavy parts with lifting
equipment of a suitable capacity.
Make sure that the units or parts are sup-
ported by appropriate harness and hooks.
Make sure that there are no bystanders
near the load being lifted.

WARNING
Handle all parts with the utmost care. Do
not put your hands or fingers between one
part and the next. Wear approved safety
garments such as goggles, gloves and
safety footwear.
Splitting
Proceed in the following way:
1. Split the clutch assembly (see section 300).
2. Disconnect the electrical connection (1) from
the horn.
3. Unscrew the clamps (1, 2) and remove the
intake sleeve (3).

6
8
SECTION200 - ENGINE

4. Remove the air intake filter (1).

5. Unscrew the bolts (1) that fix the silencer to the


exhaust manifold. Unscrew the bolt (2) that
fixes the exhaust pipe under the platform and
remove the exhaust pipe.

6. Disconnect the lubrication intake pipe (1) from the


pump (2).

7. Disconnect the return pipe (1) of the lubrication


system.

11
0^ SECTION200 - ENGINE <
8. Unscrew the relative clamps and detach the upper (1),
central (2) and lower (3) sleeves from the radiator.
9. Place two fixed stands under the axle support and one under
the engine. Hook on the chains so that the engine is well
balanced as it is lifted and fit two wooden chocks between
the support and axle to prevent the load from swing- ing.

10. Unscrew the union (1) and detach the pipe of the
front diff lock.

11. Unscrew the bolts (1) that fix the engine to the front
axle support (2).

200-34 P/N3676163M1 Edition07-2004


SECTION200 - ENGINE

12. Using a hoist (1), split the engine from the sup-
port - front axle assembly.

WARNING
Lift and handle all heavy parts with lifting
equipment of a suitable capacity.
Make sure that the units or parts are sup-
ported by appropriate harness and hooks.
Make sure that there are no bystanders
near the load being lifted.

Remounting
Bear in mind the following recommendations when remounting the engine:
- Apply the driving torque values given on page 17.

WARNING
Handle all parts with the utmost care. Do
not put your hands or fingers between one
part and the next. Wear approved safety
garments such as goggles, gloves and
safety footwear.
- Fit the support-front axle assembly back on the engine.
- Connect the pipe of the front differential lock.
- Connect and fix the upper, central and lower sleeves of the radiator and the connection bracket.
- Connect the return pipe (1) of the lubrication system.
- Position and fix the support and filter of the transmission lubricating circuit.
- Connect the intake pipe to the lubrication system.
- Position and fix the exhaust pipe.
- Position the air intake filter.
- Mount and fix the intake sleeve.
- Connect the horn connections.
- Remount the clutch assembly (see section 300).

0^ SECTION200 - ENGINE

Compression degree
(
The compression degree is a value that indicates the
quantity of air intaken and the condition of the

COMPRESSION TEST

If the engine performances are insuffi-


cient, check the compression value of each
cylinder besides the injection appa- ratus
(overhaul the atomizers and injec- tion
pump).

AWARNING
Do not use matches, cigarette lighters or
torches as light source near the machine as
it contains inflammable fluids.

sealing parts of the cylinder (rings and valves).

P/N3676163M1 Edition 07-2004 20035


The compression value in the cylinders ensures that
the cylinders themselves operate correctly in the
condition where the same amount of fuel is injected
per cylinder per phase.
Insufficient compression not only lowers the engine
performance but also prevents the fuel from burn-
ing completely as there is not enough air to achieve
a perfect combustion.
In this case, the engine will no longer operate effi-
ciently and will consume too much fuel. This leads to
smoke at the exhaust and a reduction in the exhaust
orifices.
Since the compression degree also depends on
the engine temperature (there are lower com-
pression values with a cold engine, higher ones with
a hot engine), the compression value must only be
measured when the engine has reached its
operating temperature.

Measuring procedure
1. Bring the engine to operating temperature.
2. Turn off the engine.
3. Turn the regulator knob to the STOP position to
prevent fuel from flowing to the injectors.
4. Remove the injector that corresponds to the
cylinder being examined.
5. Allow the internal combustion engine to turn
over a few times by means of the starter motor
in order to expel any carbon residues.

6. SECTION200 - ENGINE
Mount the dummy injector 001 MT MIS in
place of the one demounted previously and fit a
copper washer in between.
7. Connect the compression tester 002 MT MIS
(with an adapter and pressure gauge (1)) to
the tested cylinder and take the measurements
by allowing the internal combustion engine to
run by means of the starter motor until the
pressure gauge reading becomes stable.

8. Test the compression in the remaining cylinders


by repeating the previously described opera-
tions 4-5-6-7.
Compare the measured values with the ones in
the table below:
Compression pressure at 250 RPM. (kg/cm2)
Model Difference in the compression pressure off
MISTRAL Normal Limit the various cylinders (kg/cm2)
AMERICA
35 1 28 1 2-3
40
33 1 26 1 2-3
45
35 1 28 1 2-3
50

P/N3676163M1 Edition 07-2004 20035


Also consider that the compression decreases by about 1%
for each 100 meters of altitude above sea level and that,
depending on the engine rate, the pressure variation
presents the trends indicated in the fig. 17.
2LA0743

17

P/N3676163M1 Edition 07-2004 20035


Q
SECTION200 - ENGINE

Although the aim is to always obtain the


EU3 highest compression values, the important
thing is to make sure that the compres sion
in the cylinders is uniform as this allows the
engine to operate in a regular way.

It is advisable to check a second time if considera- ble drops in the compression in a cylinder are noted.
Before measuring, pour normal engine oil (about a spoonful) through the injector hole, into the cylinder.
Allow the engine to run so that the oil spreads over the walls of the cylinder, then repeat the test and compare the two
test values obtained.
If higher values are recorded d u ring the second test, this means that the piston rings could be worn and/or the
cylinder liners could be ovalized or dam- aged.
If the values are not higher than the previous ones, the fault will be due to the valves.
Only a slight improvement in the compression will indicate that both the valves and piston rings are in order.
Whatever the case, also consult "Troubleshooting" on page 24 - 31.
SECTION200 - ENGINE

ENGINE - OVERHAUL Demounting


The following procedure assumes that the external parts (such as the air filter, exhaust pipe and radia- tors,
which differ as to type and installation) have already been demounted and that:
WARNING
Handle all parts with the utmost care. Do
not put your hands or fingers between one
part and the next. Wear approved safety
garments such as goggles, gloves and
safety footwear.
- all sand, dust and dirt have been removed from the surface of the engine;
- the lubricating oil and coolant have been drained from the engine.

1. Remove the exhaust manifold (1).

2. Detach the intake manifold (1).


0^ SECTION200 - ENGINE <
3. Shut off the fuel tank cock.
4. Remove the high pressure fuel hose (1).
5. Remove the fuel return hose (1).
6. Slacken off the fastening nut on the injector (3)
retainer (2) and remove both.

If the injector housing (3) has remained


on the cylinder head, detach this latter
before removing the injector
(3) housing.
Seal the respective threads with tape or
some other material to prevent dust
from penetrating into the injector (4),
injection pump (5) and high pressure 20
hose (1).
Replace the protective element (2) with
a new one whenever the injector
(4) is removed.

22

200-40 P/N3676163M1 Edition07-2004


SECTION200 - ENGINE

7. Remove the valve cover unit (1).

2LA0024

23
8. Remove the rocker arm/shaft assembly (1).
9. Remove the rocker arm rod (2).

Apply a label to the rocker arm rod (2) for


each cylinder to ensure that the rods are
remounted in the right order.

10. Remove the cap (3) of the valve from the head
of the intake/exhaust valves.

11. Unscrew the fixing bolts and remove the fan (2).
12. Slacken off the fixing bolt (1, fig. 26) from the
adjuster bracket of the alternator belt, then
detach the belt itself (1).

13. Remove the alternator (2).


14. Remove the spacer of the cooling fan (4, fig. 25)
and the pulley (5, fig. 25).

Do not force the alternator (2) towards the


cylinder block as it could be damaged.
0^ SECTION200 - ENGINE <
15. Remove the lubricating oil filter unit (1).
16. Take the oil level dipstick (2) from its hole.

17. Remove the fuel return hose (2) and (3).


18. Remove the fuel filter (1).

19. Remove the thermostat unit (1).


20. Remove the pump of the cooling system (2).
SECTION 200 - ENGINE

21. Unscrew the fixing bolts (1, fig. 32) from the
cylinder head (2, fig. 32). Take particular care to
prevent the components from being dam- aged
and slacken off the bolts in the order indi- cated
below:
in the figure on the right (fig. 30) for the
three-cylinder engine (Mod. MISTRAL
AMERICA 40)

in the figure on the right (fig. 31) for the four-


cylinder engine (Mod. MISTRAL AMERICA 45/50).

22. Remove the cylinder head assembly (2).


23. Remove the head gasket (3).

L.V. = Flywheel side L.D. =


Timing system side L.A.C.
= Camshaft side L.P.I. =
Injection pump side
Q
SECTION200 - ENGINE

24. Remove the intake/exhaust valves from the cyl -


inder head in the following way:
Using a compression tool (1) 003 MT MIS,
compress the valve spring (3, fig. 34) and
remove the cotters (1, fig. 34).

Remove the valve retainer (2) and the spring


(3).
Remove the intake valve (6) and exhaust
valve (5).
Repeat the sequence of operations for the remain-
ing valves.

25. Remove the bolt (2) that connects the V-pulley


of the drive shaft (1).
26. Use a puller to take out the drive shaft pulley
(1).

Tap on the bolt (2) with a plastic mallet or


some similar tool in order to remove the
pulley (1).
SECTION200 - ENGINE

27. Remove the screws (2) that fix the spacer (1)
between the crankcase and oil sump (3).

28. Unscrew the fixing bolts (4) from the gearbox


(1).

Always remove the bolt from the reinforc- !


ing element (3) in the center of the gear- box.
When the gearbox is removed, remember
to protect the retainer seal (2) in an ade-
quate way to prevent it from being dam-
aged.

29. Remove the gearbox (1).

37
0^ SECTION200 - ENGINE
Before the injection pump (1) is removed,
check the position of the arrow on the body
<
of the pump used to time the injec tion
phase and the position of the line marked
on the gearbox flange.

30. Remove the nut from the driven gear (2) of the injection
pump (1). Take the gear out with an appropriate puller.

31. Remove the injection pump (1). Remove the lubricating oil
pump (3).

32. Remove the starter motor (2) from the gearbox


flange (1).

33. Remove the fixing bolts (1) from the flywheel on the
drive shaft (3).
34. Remove the flywheel (2).

Protect the ring gear in an adequate way to


prevent it from being damaged.
SECTION200 - ENGINE

35. Remove the retention seal box (1) by inserting a


screwdriver into the grooves on both sides of
the box itself.

Take care to protect the seal to prevent it


from being damaged.

36. Remove the spacer (1) and the oil sump (2).
Position the cylinder block assembly with
! the surface pointing downwards.
Ly Take care to protect the combustion sur-
face to prevent it from being damaged.

2LA0043

42
37. Remove the intermediate gear shaft (7), then
remove the gear itself (3).
38. Remove the bolt (5) that fixes the thrust bear-
ing (4) through the hole of the camshaft gear
(6). Remove the camshaft assembly (1).

Move the cylinder block to one side to pre-


vent the tappets (1, fig. 44) from jamming
on the cam.
Heat the gear (5) and the camshaft
assembly (1) to 180C - 200C (they are
shrunk-on) before splitting them.

39. Remove the gearbox (2) flange.

SECTION 200 - ENGINE


40. Remove the oil pump filter (2).
41. Remove the big end pin cap (4).

Make sure that the number of the big end


cap (2, fig. 45) matches the number of the
cylinder.
Make sure that the big end pin bearing (3)
does not drop off when the cap (4) is
removed.

42. Remove the piston (1, fig. 45) and connecting rod
(2, fig. 45) without having to take out the drive
shaft. To do this, proceed in the following way:
Turn the drive shaft (3) and move the piston
to bottom dead center (B.D.C.).
Remove the carbon deposits from the upper
wall of the cylinder using fine grain glass pa
per. Take care to prevent the inner sur- faces
of the cylinder from being damaged.
After having detached the cap of the big end
pin (5), turn the drive shaft and bring the
piston to bottom dead center (B.D.C.).
Take out the piston/connecting rod assem- bly
by lightly tapping on the big-end (2, fig. 45)
with the handle of a plastic mallet.

43. Remove the bolt (7) from the main bearing


support (6). Detach the cap (6) along with the
lower half bearing (5) of the main bearing.

Before taking out the drive shaft, measure the


float from this latter by placing a comparator (1,
fig. 46) on its end (3). Now proceed as described
in "Drive shaft inspections, measurements and
repairs - Drive shaft float".
SECTION200 - ENGINE

Alternatively, insert a thickness gauge straight between the bearing ring (8, fig. 45) and the thrusting surface on
the drive shaft in order to measure the float, which must be 0.090 - 0.271 mm (for all models).
If the value measured is higher than the above limit, replace the bearing ring (8, fig. 45) as described below:
1. When the ring is removed (8, fig. 45), check and
note down its position and mounting direction in
relation to the cap.
2. Make sure that the groove in the bearing ring
points outwards in relation to the cap.

44. Take out the drive shaft (3, fig. 45), taking care to prevent it from being damaged.
45. Remove the upper half bearing (4, fig. 45) of the
2LA0047
main bearing. 46
46. Remove the piston (1, fig. 45) and connecting rod
(2, fig. 45) assembly if it is still mounted.
47. Remove the tappets (1, fig. 47).

Apply a label to the tappets (1) for each


cylinder to ensure that they are remounted
in the right order.
0^ <22
SECTION200 - ENGINE
DANGER
! Do not use matches, cigarette lighters or
torches as light source near the machine as
it contains inflammable fluids.

Bear in mind the following recommendations when remounting


the engine:

- Thoroughly clean all parts if the engine must be demounted.

Work through the engine demounting opera- tions in


reverse order when remounting the engine.
The following descriptions illustrate assembly
operations where greater attention is required in
order to mount the parts in the correct way.
The driving torques of the parts are given on page
17.
Replace all the gaskets during the remounting phase
when total or partial demounting operations are
carried out.

Lubricate the parts with engine oil before the rotating


r-% components and gaskets are fitted during the
coupling phase.
Liquid seals must be used for specific coupling
surfaces when the parts are remounted:
Figure 48 - seal (1) between
crankcase - gearbox flange (2).
Figure 49 - seal (1) between flange -
gear- box cover (2).
Figure 50 - seal (1) on oil sump (2)
contact surface.
Lubricate the gasket with engine oil when the oil filter
is remounted.
i-*
SECTION200 - ENGINE

Assembly of tappets and drive shaft with main bearing caps, bearings and bearing rings
Proceed in the following way:
- Mount the tappets in their relative housings in the crankcase.
r-%
- Lubricate the housings in the crankcase with engine oil and position the main half bearings.
- Insert the lower drive shaft bearing half rings and apply grease to the shims of the second from
last main bearing to facilitate the opera- tion.
- Lubricate the upper part of the main half bearings with engine oil and mount the drive shaft, taking care to
prevent the previously mounted bearing half rings from being damaged.
- Lubricate the main journals with engine oil. Position the main bearing caps along with the relative half
bearings and mount the upper bearing half rings (on the second from last main bearing cap).
- Turn the drive shaft a few times in order to allow the various components to adapt.
- Mount the bolts (1) that fix the main bearing caps, bringing them into contact with the same, then tighten
them to the prescribed torque value.
- After the drive shaft has more or less been mounted, check the float in compliance with the procedure
described in "Drive shaft inspec- tions, measurements and repairs - Drive shaft float".
- Apply liquid seal to prevent gaps from forming in the centre. Failure to do this could lead to oil leaks, etc...
(see section 100).

51
Assembly of pistons complete with piston rings,
pins,
0^ connecting rods, caps and bearings <22
ProceedSECTION200 - ENGINE
in the following way:

Lubricate the pistons, piston rings and cylinder liners


with engine oil before mounting them.
Mount the piston rings on the piston housings with
the manufacturer's mark (1) near the indentation,
pointing upwards (combustion chamber) and using
tool 004 MT MIS.

- Make sure that the piston rings (1, 2 and 3)


are free to move in their housings and that the
indentations are staggered 120 in relation to each
other.
- Mount the pistons complete with connecting
rods into the crankcase. Make sure that the
connecting rod matches the right cylinder.

Mount tool 005 MT MIS in order to fit the pistons into the
cylinder liners. Proceed with care to prevent the
indentations described in the previous step from being 53
staggered.

Mount the pistons complete with connecting rods


<S> into the crankcase. Make sure that the
connecting rods and cylinders match and that the
positions of the connecting rods comply with the
indications given by the marks on the connecting
rods themselves.

Key:
1. D.I. mark.
Turn the rotating stand through 180 and clean
2. Cylinder size
the top surface of the crankcase.
indication
Bring the pistons (2) to TDC (top dead center)
3. Stamped
and mark.
use a comparator with magnetic base (l) to
4.
checkAlignment
Positionthat
the
mark.
thebig
extent
end to which
caps the top with
complete sur face of
their
L.A.C.
the = Camshaft
pistons
relative bearings,sideon inthe
projects relation to theand
drive shaft crankcase
tighten
L.I.does
= Injector
the fixing side L.V.
not exceed
bolts thea prescribed
to 44.1 - 54.0 toler-
Nmance
(4.5value.
- 5.0
= Flywheel side
kgm) torque value. 55
56
Assembly of timing, lubrication, starting,
recharging, cooling and fuelling components
- Remove the gearbox flange.
- Shrink-on the camshaft gear to the shaft itself.
- Fit the camshaft assembly back into the crank-
case and fix the relative crankcase thrust bear-
ing with the bolts.
- Fit the intermediate gear back on the relative
shaft.
- Fit the intermediate gear back shaft into the
crankcase.
Fix the spacer between the crankcase and oil sump,
to the crankcase itself, then fix the sump to the
spacer and tighten the relative bolt. Remount the
drive shaft gasket box.
Fit the flywheel back on to the drive shaft and
tighten the fixing bolts to a 83.4 - 88.3 Nm (8.5 - 9
kgm) torque value.
Fit the starter motor back on to the gearbox flange.
Remount the lubricating oil pump.
Mount the driving gear of the injection pump back
on to the pump itself.
Remount the injection pump and proceed with the
timing operation.
Mount the gearbox back on to the crankcase with
the flange in between.
Remount the screws that fix the spacer (crank-
case-oil sump) to the gearbox.
Fit the V-pulley back on to the drive shaft and fix it
in place by tightening the relative bolt to a 112.8 -
122.6 Nm (11.5 - 12.5 kgm) torque value.
- After the gears have been mounted,
check to make sure that the gear train
has been cor- rectly timed as indicated
in "Gear Inspections, Measurements and
Repairs - Gear Train".
- Apply lubricating oil through to the
r-fc
lower sur- face (dotted part in the
figure) of the valve guide (1) before
inserting the valve stem.
- Fit the springs and cotters back into the
cylinder head and valves (intake and exhaust).

SECTION200 - ENGINE

Proceed by mounting (and correctly position- ing) the


cylinder head, thoroughly cleaning and eliminating the
grease from the top part of the crankcase.
Fit the cylinder head assembly and tighten the fixing
bolts to a 85.3 - 91.2 Nm (8.7 - 9.3 kgm) torque value
in the indicated sequence:
in the figure on the right (58) for the three- cylinder
engine (mod. MISTRAL AMERICA 40)
in the figure on the right (59) for the four- cylinder
engine (mods. MISTRAL AMERICA 45/50).

Key:
L.A.C. = Camshaft side 58
L.S.I. = Gearbox side
L.P.I. = Injection pump side
L.V. = Flywheel side

- Remount the pump of the cooling system and


the thermostat unit.
- Re-connect the coolant delivery hose to the
pump.
- Remount the fuel filter.
- Remount the fuel return hoses.
- Fit the dipstick back in place.
- Remount the lubricating oil assembly.
- Remount the spacer of the cooling fan and the V-
pulley.
- Remount the alternator.
- Remount the cooling fan-alternator belt, then
remount the fan. Consult "Belt tension inspec-
tion" to establish the correct belt tension.

59
60
- Remount the rocker arm rods in compliance with
the rods-cylinders matches defined by labelling
during the demounting phase and by first
applying a film of lubricating oil in the hatched
part of the rocker arm rod as shown in the
figure.
- Remount the rocker arm/shaft assembly.
- Remount the injector retainers and lock them to
the injectors with the retainer nuts (also replace
their protection elements).
- Remount the fuel return hose.
- Remount the high pressure fuel hose.
- Re-open the fuel tank cock.

- Remount the intake manifold.


- Remount the exhaust manifold.
- Top up the level of the lubricating oil and cool-
ant.
After the engine has been completely remounted
and the fluid levels topped up, proceed with the
adjustments and inspections described in the fol-
lowing sections:
- "Valve play adjustment",
- "Checking the cooling circuit and radiator for
leaks",
- "Idling rate adjustment (minimum and maxi-
mum)"
SECTION 200 - ENGINE

Valve play adjustment


1. Check the valve play when the engine is cold.
2. Move the piston to top dead center (TDC) in the
cylinder where the measurements are being taken.
3. Using a spanner (2), slacken off the lock nut and
then the adjuster screw, using a screw- driver (1).
Make sure that the valve cap is cor- rectly positioned
and free from dirt deposits.

^E37

4. Insert a thickness gauge with a play value (G) of:

1. 15 - 0.25 mm

between the rocker arm and cap of the intake/


exhaust valve.
Tighten the adjuster screw (1) until the rocker arm
pad touches the thickness gauge and fix with the lock
nut (2).
62

Replace the valve cap (1) if it is worn or


na3 damaged.
Make sure that the cap is correctly
positioned on the top of the intake/
exhaust valves.

Key:
1. Normal
0^ position <22
2. SECTION200
Wrong - ENGINE
position

How to check the belt tension


2. Press with the hand in the middle of the belt between the
alternator (3) and the cooling pump (1) in the direction
shown by the arrow. If the belt gives (F):

F = 10 - 15 mm

the belt tension is correct.


2. If the belt fails to give to the prescribed values, adjust the tension by changing the position of the
alternator (3) by means of the adjuster bracket (1) and bar (2).
SECTION200 - ENGINE

INJECTOR NOZZLE AND INJECTION PRESSURE


Carefully remove the carbon deposits from
the injector before proceeding with the
inspections.

MEASURING AND MONITORING

Injection pressure measurement

1. Connect the injector (1) to the high pressure hose of


the injector test instrument (2).
2. Slowly operate the lever of the instrument (2) and
note down the value indicated by the pressure gauge
when the injector (1) starts to spray.
Thickness of the Injection pressure adjustment
adjuster ring (mm)
Consult the table on page 8 for the injec -
Increase the thickness of the
tion pressure values of each engine.
0.13; 0.15; 0.18; adjuster ring by 0.1 mm to
0.4; 0.5; 0.8 increase the injection pressure
3. If the pressure measured is less than the pre- scribed by about 19 bar
value, replace the adjuster ring of the injector with a
thicker one calculated according to the indications
given in the table below:

View of the injector parts:


1. Fuel return hose coupling.
2. Injector body.
3. Adjuster ring
4. Spring
5. Spring housing
6. Atomizer retaining spacer.
7. Atomizer
8. Atomizer housing
Jet inspection
Operate the lever (3) of the injector test instrument (2) 4
- 6 times, depending on the prescribed injec- tion
pressure (See page 8) while checking the jets.
- Make sure that the jet is neither a continuous nor
fragmentary flow. Clean or replace the atomizer (7,
fig. 67) if this is the case.
- Make sure that the jet of fuel around the median line
of the injector is tapered in shape and that the
delivery angle is about 150. Clean or replace the
atomizer if this is not the case.
- Check the injector with the relative measuring
instrument. Tighten and repeat the test if there is an
excessive fuel return from the recovery joint. Replace
the entire atomizer unit if the leaks persist.
Refer to the figure on the right in order to define
the shape of the jet:
normal jet see fig. 69;
abnormal jet see fig. 70;
Place a sheet of white paper 30 cm under the
atomizer and make sure that the jet forms a
perfect circle.
After injection, make sure that no fuel drips from
the injector.
Make sure that there are no fuel leaks from the
injection hole if the pressure is slightly lower
than the prescribed value.
2LA0067

69
2LA0068

70
SECTION200 - ENGINE

Atomizer valve sliding test


1. Thoroughly clean the atomizer valve (1) with
clean diesel fuel.
2. Keep the body (2) of the atomizer in a vertical
position and lift the valve about 1/3rd of its
length.
3. Make sure that the valve drops back easily by
itself when released. In this case, the valve is in
a perfect condition.

If the atomizer is new, remove the adhe-


sive film and immerse it in clean diesel fuel
(or another similar product) to clean the
internal surfaces and remove all traces of
rust inhibitor before it is used. New
atomizers are spread with rust inhibitor oil
and are covered with adhesive film to pro-
tect them from the air.

Identification number of the atomizer


casing
Consult the following explanation to interpret the
identification number (2) of the atomizer casing (1):

Y DLL A - 150 P 244JO

Model code
Dimensions: d imension
F d imension S
Injection angle
Atomizer positioning
angle CodeA: angled No
code: not angled
Type : DLL (sem i-long
type) YANMAR

INJECTION TIMING ADJUSTMENT AND


MONITORING

1. Use the pulley (1) of the drive shaft and turn the
engine in the indicated direction.

P/N3676163M1 Edition 07-2004 20061


SECTION200 - ENGINE
3. Check the injection timing on the
delivery valve of the injection pump
Q
for cylinder N 1 (1). (Cylinder
numbering is sequential beginning
with cylinder N 1 from the flywheel
side).

4. Turn the drive shaft in the indicated


direction until the diesel fuel level
reaches the upper limit of the spring
casing of the delivery valve.
IDLING RATE ADJUSTMENT
2LA0072
(MINIMUM AND MAXIMUM)

1. Allow the engine to warm up


then gradually accelerate to top
rate (see pages 3, 4 and 5).
2. If the top idling rate differs from
the prescribed value, adjust by
means of the maximum idling
rate adjuster screw (1).
3. Allow the engine to idle (see
pages 2, 3 and 4) by turning the
minimum idling rate adjuster
screw (2).

2LA0073

4. Find the timing notch on the flywheel (1) through


the access hole (2).

Consult page 8 for instructions about how


to time the injection phase of each engine
model.

2LA0074

5. If the timing values differ from those pre-


scribed, adjust by turning the injection pump
towards the engine or in the opposite direction
after having slackened off the lock nut (1) on it.

Move the injection pump away from the


engine if injection is delayed.
Move the injection pump nearer to the
engine if injection is in advance.

2LA0075

200-62 P/N3676163M1 Edition 07-2004


SECTION200 - ENGINE
HOW TO CHECK THE COOLING SYSTEM AND
SECTION200 - ENGINE

Q
RADIATOR TO FIND LEAKS
1. Make sure that the coolant in the radiator is at
the right level.
2. Start the cooling pump and make sure that
there are no leaks.

78

The cooling circuit can only be efficiently


checked when the engine is hot.

200-94 P/N3676163M1 Edition 07-2004


SECTION200 - ENGINE
SENSOR INSPECTION
Q
Thermostat
1. Immerse the thermostat (1) into a vessel fuli of water
and heat this latter while measuring the temperature.
2. Make sure that the thermostat operates at the
temperature of 69.5 - 72.5C, measured with a
thermometer (2). Failing this, replace it as it is
defective.

Thermal switch
1. Immerse the thermal switch (1) into a vessel
containing antifreeze or oil.
2. Heat the liquid and measure its temperature
with a thermometer (2).
3. If the tester connected to the prods (2) gives
continuity values at the temperature of 107 -
113C, then the thermal switch is operating
correctly. Failing this, replace it as it is defec-
tive.

200-95 P/N3676163M1 Edition 07-2004


SECTION200 - ENGINE
Hydraulic switch
1. Remove the connector from the hydraulic switch.
SECTION200 - ENGINE

Q
2. Start the engine and move the tester probes (1)
near to the switch terminal and cylinder block
(2).
3. If the tester gives a no-break indication, this
means that the hydraulic switch is defective and
must therefore be replaced.

CYLINDER HEAD INSPECTIONS, MEASUREMENTS


AND REPAIRS
Warping and inspection of the combustion
surfaces
1. Remove the intake/exhaust valves and the

Thoroughly clean the parts before pro-


ceeding with the inspections.

Do not use solvents to clean the parts. Use


cleaning products that comply with the
standards in force.

injector from the cylinder head. Clean the sur-


face of the cylinder head.
2. Place a straightedge (1) along each of the four
sides and on each diagonal of the cylinder head.
Measure the play between the straightedge and
the combustion surface with a thick- ness gauge
(2).
3. Compare the result with the reference value
which, in the specific case of a warped cylinder
head combustion surface, is:

0^ <
SECTION200 - ENGINE

for the normal dimension < 0.05 mm for the


limit (of wear) dimension= 0.15 mm
4. Check to make sure that the combustion surface
is not discoloured, broken or cracked.
Valve impression
1. Lengthy use and repeated lapping can lead to a drop in
combustion efficiency. Measure the depth (H, fig. 84) of
the valve impression with a depth micrometer. Replace
the valve if the impression is deeper than normal.

200-96 P/N3676163M1 Edition 07-2004


SECTION200 - ENGINE
S
t
Q
a
n
d
a
r
d

v
a
l
u
e
s
,

f
o
r

d
i
m
e
n
s
i
o
n

(
H
)
,

t
o

c
o
m
p
a
r
e

w
i
t
h

200-67 P/N3676163M1 Edition 07-2004


SECTION200 - ENGINE
h
e
Q
m
e
a
s
u
r
e
d

v
a
l
u
e
s
,

a
r
e

g
i
v
e
n

i
n

t
h
e

t
a
b
l
e

o
n

p
a
g
e

1
0

200-68 P/N3676163M1 Edition 07-2004


SECTION200 - ENGINE
.
Q
1 84
0

1.

2.

3.

.
Valve housing width and angle
Remove the carbon deposits from the surface of the
valve housing.
Measure the width and angle of the housing using a
slide (1) and angle gauge.
Compare the obtained results with the standard values
given on page 10.

2LA0082

200-69 P/N3676163M1 Edition 07-2004


SECTION 200 - ENGINE

Valve housing intervention procedur


1. When the surface of the valve housing appears to be slightly
worn or rough, lap with a valve compound mixed with oil to
obtain a smooth mixture.
2. When the valve housing is very worn or rough, the defect can be
corrected with a grinder tool (1) or valve housing mill and
finished as described in point 1.

Grinder Angle (0)

Intake valve

O OU)
Exhaust valve

LO
o
Grinding and milling tool use procedure
1. Correct the roughness of the valve housing surface with a grinder or milling tool.

2. When the width (L) of the valve housing (1) is more than the
initial value, correct it by grinding the surface with a grinder held
at 70 or with a milling tool. After this, grind the housing with a
grinder held at 15 until the normal width is obtained.

If a milling tool is used, apply an even


pressure and avoid moving the tool in a
discontinuous way.

3. Soften the valve compound by mixing it with oil and


finish the valve housing by lapping.

Before working on any of the valves, make


sure that you have measured the gap
between the outer diameter of the valve
stem and the inner diameter of the valve
guide. If the gap exceeds the required limit,
replace the valve or valve guide before
working on the surface of the housing. (The
assembly play between the valve and valve
guide is given on page 7).
SECTION 200 - ENGINE

1. After the work on the valve housing


has terminated, thoroughly clean it and
the cylinder head with diesel fuel or
another similar product. Carefully
remove the valve or surfacing com-
pound.
2. Repeat points 3 and 4 if the contact is
poor.
4. Terminate by lapping the valve with oil only.
Valve housing removal
1. Grind the circumference of the intake/exhaust valve head in area B to obtain a smaller outer diameter of
the valve housing.
2. Grind the circumference of the valve stam end 88
in area A until the same dimensions of the cot-
ter housing race diameter are obtained.
3. Weld the intake/exhaust valve head (1) to the
housing (2) in three points.
4. Tap on the end of the intake/exhaust valve stem
to extract the valve housing.

Valve housing insertion


1. Place the valve housing (1) in a vessel contain-
ing liquid nitrogen, ether or alcohol and dry ice in order to cool it sufficiently.
2. Heat the cylinder head around the valve housing to 80 - 100C with a drier.
3. With the new intake/exhaust valve, firmly insert
the sufficiently cooled valve housing into the
cylinder head, tapping lightly on the valve head.
4. Allow the cylinder head to cool down to a nor-
mal temperature.

89
SECTION200 - ENGINE

Valve stem wear and warping


Replace the valve stem if it is very curved or worn.
In this case, also replace the valve guide.

Valve stem and valve guide


The assembly play is the difference between the
inner diameter (I.D.) of the valve guide measured
with a three-point micrometer (able to measure an
inner diameter between 4 mm and 8 mm) or a cyl-
inder gauge (able to measure an inner diameter of 6
mm or more) and the external diameter (E.D.) of
the stem, measured with a micrometer. Replace both
the intake/exhaust valve and the valve guide when
the play is near to the limit value.
Compare the results obtained with the standard
values given on page 10.

Valve head thickness


Measure the thickness (S) of the valve head with a
micrometer.
Replace the valve if the measured value is near to
the wear limit.
Compare the results obtained with the standard
values given on page 10.

0^ <
SECTION200 - ENGINE

92
3. Finish off the inside after the valve guide has
been inserted.

Valve guide replacement


1. Remove the valve guide (2) from the cylinder
head with the relative puller 006 MT MIS (1).
2. Place the valve guide in a vessel containing liq-
uid nitrogen, ether or alcohol and dry ice in
order to cool it. Fit the sufficiently cooled valve
guide into the cylinder head and tap it lightly
with the relative tool 007 MT MIS in order to
seat it correctly.

P/N3676163M1 Edition 07-2004 20069


4. Check the projection (S) of the valve guide.
^E37
Compare the obtained results with the standard 93
values given in the table on page 10.
Valve stem seal
Replacement frequency
- When the oil leaks are excessive.
- When the seal has been removed from the valve
stem.
- When the intake valves are
2LA0091
removed. Precautions for
installation.
Make sure that the entire valve stem surface is
smooth and apply a film of lubricating oil to the
stem before remounting the valve.

Key
1. Valve shank seal
2. Valve guide
3. Cylinder head

P/N3676163M1 Edition 07-2004 20069


SECTION 200 - ENGINE

Valve spring inspection


1. Check to make sure that the valve spring is not
cracked or corroded.

2. Use a gauge (1) to measure the free length


(length of the spring) and its slant (squareness
of the coil side) using the square (1, fig. 96).

Compare the obtained results with the standard


values given in the table on page 10.

Key
1.
Squar
e
2. Slant
error
3. Free
length
Spring cap and cotter inspection
Check the contact between the inner surface of the
spring cap and the circumference of the cotter, and
the contact between the inner surface of the cotter
and the race on the head of the valve stem. If the
contact is irregular or the cotter has lowered,
replace it with a new one.
Q
SECTION200 - ENGINE

CRANKCASE AND CYLINDER LINER INSPECTIONS, MEASUREMENTS AND REPAIRS


Crankcase inspection
1. Check to make sure that there are no water or oil leaks or cracks in the crankcase. If you think that there
may be cracks, check with a special colouring substance able to detect cracks that are not visible to the
naked eye.
Thoroughly clean the parts before pro-
ceeding with the inspections.

Do not use solvents to clean the parts. Use


cleaning products that comply with the
standards in force.

2. Replace the crankcase if it is seriously or irrep- arably


damaged.
3. Thoroughly clean all oil holes. Make sure that they
are not clogged.

200-73 P/N3676163M1 Edition07-2004


SECTION200 - ENGINE

Measurement of cylinder liner bore and warping


Measure the bore of each cylinder with a bore gauge (1, fig. 98). Measure the cylinder in point A, about 20
mm under the liner tip and in points B and C, at the same
distance (AB = BC).

The measurements must be made in A, B


and C along directions dA and dB.

Calculate the warp (roundness and cylindricity of each


cylinder) using values measured in the follow- ing way:
- Roundness:
Difference between the maximum and minimum bore
values in the same radial section of each liner.
- Cylindricity
Difference between the maximum and minimum bore
values along the liner axis.
Lapping (lapping and reaming) must be carried out when the
values measured exceed that limit.

2LA0097

99

For oversized pistons and piston rings, see


pages 9 and 10.

Compare the obtained results with the standard


values given in the table on page 8.

Lapping
Lapping procedure
Lap or ream the cylinder in the case of irregular
wear, defects or other types of damage. Slight and
irregular wear, small cracks, etc., can be smoothed
with a flexible fine-finishing brush (1) mounted on
an electric drill (2). If the wear is greater and more
irregular, it is advisable to ream and then lap the
cylinder. It is important to evaluate whether the cyl -
inder can become perfectly round after lapping,
reaming or both, and to bear the maximum wear
degree in mind. Moreover, also carefully check out
whether oversized piston rings and pistons can be
used.
2LA0098

100

P/N3676163M1 Edition 07-2004 200-74


0^ SECTION200 - ENGINE <L
Use of the flexible fine-finishing brush
It is advisable to use a flexible fine-finishing brush for surfacing
purposes.

Tools required
Flexible brush for fine-finishing (1), electric drill and
surfacing liquid (1, fig. 101) made from a mixture of 50%
engine oil (2, fig. 101) and diesel fuel (3, fig. 101).
Instructions for use
1. Apply the surfacing liquid to the flexible fine
finishing brush.
2. Start the brush turning and move it into the
cylinder, working up and down for about 30 sec
at an angle of 30 - 40, as indicated by the
cross-hatched area in the figure.
3. Remove the brush from the cylinder while it is
still turning.

WARNING
Use the flexible fine-finishing brush at a
2LA0101
speed of 300 - 1200 RPM. Use of the
brush at a higher speed could be dan- 103
gerous.
Never move the brush into the cylin der
or take it out when the electric drill is
off.

200-75 P/N3676163M1 Edition07-2004


SECTION200 - ENGINE

ROCKER ARM INSPECTIONS, MEASUREMENTS AND REPAIRS


Measurement of the outer diameter of the rocker arm pin and inner diameter of the rocker arm
The assembly play is the difference between the inner diameter of the rocker arm (1) measured with a cylinder

Thoroughly clean the parts before pro-


ceeding with the inspections.

Do not use solvents to clean the parts. Use


cleaning products that comply with the
standards in force.
104
gauge and the outer diameter of the rocker arm pin
(1, fig. 105), measured with a micrometer. When
the assembly play is near to its limit, the pin and
rocker arm must be replaced. Compare the obtained
measuring results with the standard values given in
the table on page 11.

105
0^ SECTION200 - ENGINE <L

Tappet rod curve inspection, measurement of the


outer diameter of the tappets and inspection of the
contacting surfaces
Place the tappet rod on a surface plate and, using a thickness
gauge (1) as shown in the figure, meas- ure the distance
between the rod and the surface itself. Also measure the outer
diameter of the tappets (1, fig. 107) with a micrometer.
Compare the obtained measuring results with the
standard values given in the table on page 11.

106

Other inspections
Rocker arm pin spring
Check to make sure that there are no traces of cor-
rosion or wear on the rocker arm pin spring. Replace it if
this is the case.
Wear on the rocker arm pad (area A) and
intake/exhaust valve cap.
Check the contact surfaces of the intake/exhaust valve rocker
arm pad. Replace them if one of the two shows signs of
abnormal wear or flaking.
SECTION200 - ENGINE

Check the point in which the valve play adjuster


screw (1, fig. 108) touches the tappet rod in area B.
Replace the rod (2, fig. 108) or the adjuster screw
(1, fig. 108) if it appears worn or flaking (see fig.
109).

Valve wear:
1. Irregular contact surface.
2. Regular contact surface.

PISTON AND PISTON RING INSPECTIONS, MEASUREMENTS AND REPAIRS

Thoroughly clean the parts before pro-


ceeding with the inspections.

Do not use solvents to clean the parts. Use


cleaning products that comply with the
standards in force.
Piston inspection
1. Remove the carbon deposits from the head and from the combustion surface of the piston to prevent it
from being damaged. Check to make sure that there are no traces or breakage or other damage.
2. Check the circumference and housing of the piston ring and replace it if it is worn or damaged.

Measurement of the outer piston diameter


Measure the outer diameter of the piston (1) in a vertical direction towards the pin hole and at dis- tance

d = 22 - 25 mm

from the bottom end of the piston.


0^ SECTION200 - ENGINE <
Compare the obtained measuring results with the
standard values given in the table on page 11.

Shape of the piston rings


To identify the piston rings, refer to fig. 112, in
which:
1. Upper piston ring.
2. 2nd piston ring (the same for all models)
3. Oil scraper ring (the same for all models)
The section of the upper piston ring is given in
the following table:

Upper piston ring (all


models)

Measurement of the groove width of the piston


ring, the piston ring and the distance between
ends
1. To measure the width of the groove, first
measure the width (L) of the piston ring (2, fig.
114), then fit it into the carefully cleaned
groove. Insert a thickness gauge (3, fig. 114)
between the piston ring and groove to measure
the distance.
2. Calculate the width of the piston ring groove,
adding the width of the ring to the measured
side play G.
Compare the obtained measuring results with the
standard values given in the table on page 13.

2LA0111

113
2LA0112
114

SECTION200 - ENGINE

To measure the distance between the ends, push the piston ring (1) into the cylinder liner (2) using the piston head,
and insert a thickness gauge into the gap. If the cylinder liner is worn, measure the distance (L) between the ends
after having pushed the piston ring in the point in which the cylinder liner is less worn (about 30 mm from the bottom
end of the cylinder liner).
Compare the obtained measuring results with the standard values given in the table on pages 13 and 14.
Q
1. SECTION200 - ENGINE

Piston ring assembly


Use tool 004 MT MIS and insert the piston ring into
the groove, with the manufacturer's mark (1) near
the piston ring joint pointing towards the combustion chamber
side. When the spring ring has been fitted, make sure that it is
free to move.

117

2. Stagger the gaps between the ends of the pis-


ton rings at intervals of 120, making sure
that they are not aligned along the piston.
Lubricate the circumference of the piston
with oil.

Key
1. Upper piston ring.
2. 2nd piston ring.
3. Oil scraper ring
4. Position of the upper piston ring joint.
5. Position of 2nd piston ring joint.
6. Position of the oil scraper ring joint.
Measurement of the outer diameter of the pin and relative hole
1. Measure the outer diameter of the pin (1) and hole in the points indicated by the arrow. Compare the
obtained measuring results with the standard values given in the table on page 12.

2. Replace the pin if it is too worn.


SECTION 200 - ENGINE

Lubricate the pin (1) with oil before fitting it into the
piston. Now position the piston ring (2) in the piston
housing.

0^ <
SECTION200 - ENGINE

CONNECTION ROD INSPECTIONS,


MEASUREMENTS AND REPAIRS
Visual inspection
Thoroughly clean the parts before pro-
ceeding with the any of the operations.

Do not use solvents to clean the parts. Use


cleaning products that comply with the
standards in force.

Check the area near to the edge in the chamfered part and
the shaped part between the big end and small end of the
connecting rod. Also check the area near the oil hole of the
small end bush to make sure that there are no signs of
cracks, warp- ing or discolouring.

Twist and parallelism measurement


Measure the twist (T) and parallelism (P) by using a
connecting rod aligner (2).
Compare the obtained measuring results with the
standard values given in the table on page 14.
SECTION200 - ENGINE

2.
Measurement of the bush and connecting rod pin
play
1. To measure the connecting rod pin and bush gap,
measure the inner diameter of the bearing and
the outer diameter of the connecting rod pin,
then calculate the difference between the two
values.

To measure the inner diameter of the con-


necting rod pin bearing, mount this latter
on the connecting rod and tighten the bolt
to the prescribed torque value, i.e.

44.1 - 54.0 Nm

checking to make sure that each of the


bearings is mounted in the right position.
After this, measure the dimension with the
gauge (1).

Compare the obtained measuring results with the standard values given in the table on page 14.
Replace the connecting rod pin bearing if the gap measured is near to the wear limit or exceeds it. If the bearing is
irregularly or excessively worn, grind the connecting rod pin and use an oversized bearing.

Measure the play between the pin bush and the pin itself
Use a cylinder gauge (1) to measure the play. Measure the inner diameter of the pin bush and the outer
diameter of the pin and note down the difference between the two values.
Compare the obtained measuring results with the standard values given in the table on page 14.

2LA0121

123
Q
SECTION200 - ENGINE

Checking the connecting rod pin bearing contact


Make a mark with blue ink on the upper surface of
the connecting rod pin bearing (1). Fit the bearing in
the connecting rod and tighten the bolt on to the
drive shaft to the indicated torque value (see page
15) to check the bearing contact. The connecting rod
pin bearing contact is acceptable if the blue col-
oured contact surface occupies 75% of the total
surface or more.

Mounting the piston and connecting rod


Mount the piston with the connecting rod, with the
mark (2, fig. 124) punched on the big end pointing
towards the fuel injection pump. Mount the piston so
that the combustion chamber cavity (and the D.I.
mark) are on the injection pump (L.P.) side, viewed
from above.

Key
L.C. = Camshaft side
L. P. = Injection
pump side
M.Y. = Yanmar trademark
D.I. = Code
SECTION200 - ENGINE

Connecting rod side play


1. After having mounted the connecting rod on the
drive shaft (1), tighten the connecting rod cap
fixing bolts to the indicated torque value (see
page 14).
2. Measure the side play by inserting a thickness
gauge (2).
Compare the obtained measuring results with
the standard values given in the table on page
12.
Replace the bearing of the connecting rod if the
3. value is higher than normal.

0^ SECTION200 - ENGINE <L

CAMSHAFT INSPECTIONS, MEASUREMENTS


AND REPAIRS
Camshaft float
Thoroughly clean the parts before pro-
ceeding with the any of the operations.

Do not use solvents to clean the parts. Use


cleaning products that comply with the
standards in force.

1. before removing the camshaft, measure its


float (4) by placing a comparator against the
gear (1).
Compare the obtained measuring results with
the standard values given in the table on page
15.
2. Replace the thrust shim (2) if the measured
value exceeds the tolerated limit.
Visual inspection of the camshaft
Check the tappet contact surface on the cam. Make
sure that the bushes are not worn or seized and that
the camshaft gear (1) is not damaged.
2LA0125

127
SECTION200 - ENGINE

Camshaft incurvation measurement


1. Support the camshaft with V-blocks (1).
2. Using a comparator (2), measure the eccentric- ity of the main journal in
the center of the camshaft, by allowing this shaft to turn.
3. Consider 50% of the measured eccentricity as incurvation value.
Compare the obtained measuring results with the standard values given in the
table on page 15.

1. Intake/exhaust cam height measurement


Make the measurements by positioning the micrometer (1) as shown in the figure.
2. Compare the obtained measuring results with the standard
values given in the following table.
MISTRAL AMERICA 40-
45-50

Value Value at
nominal limit of
(mm) wear
(mm)
Cam Intake 38.635 - 38.40
height (H) cam 38.765
Exhaust cam 38.635 - 38.40
38.765

2LA0127

129
SECTION200 - ENGINE Q

Measurement of the play between the camshaft pins


and their relative bushes
1. Measure the outer diameter of the camshaft pins with
a micrometer, in the positions shown in figure 130.
2. Measure the inner diameter of the bush with a hole
gauge after having inserted it into the engine block.
3. Calculate the play according to the distance between
the inner diameter of the bush and the outer
diameter of the pin.
Compare the obtained measuring results with the
standard values given in the table on page 15.

Key
L.V = Flywheel side L.I. = Gear side

DRIVE SHAFTINSPECTIONS, MEASUREMENTS AND REPAIRS


Drive shaft float
1. Place a comparator against the end of the shaft before removing the actual drive shaft and at the moment
of assembly.
2. Force the drive shaft on both sides in an axial direction to measure the play. Alternatively, insert a
thickness gauge directly between the bearing ring on the support and the shaft itself, in order to measure
the float.

Thoroughly clean the parts before pro-


ceeding with the any of the operations.

Do not use solvents to clean the parts. Use


cleaning products that comply with the
standards in force.

If the value exceeds the limit one, i.e.:


0.090 - 0.271 mm replace the bearing ring.

2LA0047

131
SECTION200 - ENGINE

Checking the colour of the drive shaft


1. Clean the drive shaft and check it with a col-
ouring substance to make sure that there are no
cracks too small to be seen by the naked eye, or
with a Magnaflux system (magnetic crack
detector).
2. Replace the drive shaft if it is cracked or seri-
ously damaged. Repair or grind the shaft if it is
only slightly damaged.

Bearing inspection
Make sure that the bearings do not show signs of
flaking, fusion or seizing and check the condition of
the contact surface. Replace the bearings if they are
defective.

Drive
shaft incurvation
1. Place V-blocks (1) and (2) at both ends of the
main journals.
2. Measure the eccentricity of the central main
bearing with a comparator while turning the
drive shaft, and make sure that its incurvation
value (I) does not exceed the tolerated limit
value, i.e.:
0.02 mm
0^ SECTION200 - ENGINE <
Measurement of the connecting rod pin and main bearing
1. Using a micrometer (1, Fig. 135), measure the outer diameter,
the roundness and taper of the connecting rod pin and that of
the main jour- nal. Check in the points shown by the arrows
in figure 134.
Compare the obtained measuring results with the
standard values given in the tables on pages 14 and
15.
2. The pins can be ground if the irregular wear or
roundness exceed the tolerated limit, but the value of
the outer diameter is within the limits.
3. Replace the drive shaft if it is not possible to
return within the tolerated values even after
grinding.
A 0.25 mm oversized bearing is available for the
connecting rod pin.
SECTION200 - ENGINE
136

Precautions for bearing assembly


- Remember that the lower half bearing of the
main bearing (cap side) does not have an oil
groove.
- Consider that the upper half bearing of the main
bearing (cylinder block side) has an oil groove.
- Check the alignment order in the cylinder block.
- Position the "FW" mark on the main bearing cap
towards the flywheel side.
- Position the thrust shims towards the flywheel.

Key
1. Main bearings (basic).
2. Thrust shims (gear side).
3. Main bearings.
4. Main bearing cap.
5. Thrust shims (flywheel side).
6. Main bearing cap (basic).
7. Main bearing bolt.

0^ <22
SECTION200 - ENGINE

GEAR INSPECTIONS, MEASUREMENTS AND


REPAIRS
Gear inspections
Thoroughly clean the parts before pro-
ceeding with the any of the operations.

Do not use solvents to clean the parts. Use


cleaning products that comply with the
standards in force.

Check the gears and replace them if their teeth are


damaged, worn or cracked.

Play measurement
Appy a comparator on the pitch circumference of the
gear and measure the play.
Compare the obtained measuring results with the
standard values given in the table on page 15.

Checking and measuring the intermediate gear


shaft and the gear itself
1. Measure the inner diameter of the bush (2) and
the outer diameter of the intermediate gear (1)
shaft (3).
Compare the obtained measuring results with
the standard values given in the following table.
MISTRAL AMERICA 40-
45-50
Value at
Value limit of
nominal wear
(mm) (mm)

Outer shaft 45.950 -


diameter 45.975 45.93

Intermediate Inner bush 46.000 -


diameter 46.025 46.08
gear
0.025 -
Assembly play 0.075 0.115

2.
Replace the bush or the gear shaft if the
assembly play exceeds the wear limit.
SECTION200 - ENGINE

3. Check to make sure that the oil hole in the intermediate gear shaft and in
the bush is a through hole.

Gear train
After all the gears have been mounted, check to make sure that alignment
marks A, B and C of the intermediate gear are aligned with those of the
injection pump, camshaft and drive shaft gears.

1. Injection pump gear. 5. Lubricating oil pump gear.


2. Camshaft gear 6. Intermediate gear.
3. Power take-off (on request) 7. Rotation direction.
4. Drive shaft gear.

138

0^ SECTION200 - ENGINE <L

OIL PUMP INSPECTIONS, MEASUREMENTS AND


REPAIRS
Play between the external rotor and pump casing
Thoroughly clean the parts before pro-
ceeding with the any of the operations.

Do not use solvents to clean the parts. Use


cleaning products that comply with the
standards in force.

Insert a thickness gauge (3) between the external


rotor (1) and the pump casing (2) and measure the
play. 139
2LA0138
Compare the obtained measuring results with the
standard values given below:
Nominal play: 0.10 - 0.16 mm
Play at wear limit: 0.25 mm

Play between inner and outer rotor


Insert a thickness gauge (3) between the upper part
of the inner rotor tooth (1) and the upper part of
the outer rotor tooth (2) and measure the play. Compare the obtained measuring results with the standard
values given below:
Play at wear limit: 0.15 mm
SECTION200 - ENGINE

Float between the pump casing and the inner and outer
rotor
Place a straightedge (1) against the end of the pump (2)
and insert a thickness gauge (3) between this and the
rotors in order to measure the float. Compare the
obtained measuring results with the standard values
given below:
Nomina play: 0.03 - 0.09 mm
Play at wear limit: 0.15 mm

Play between the rotor shaft and housing hole


Measure the outer diameter of the rotor shaft and the diameter of the housing hole and calculate the
difference between the hole diameter and shaft diameter.
Compare the obtained measuring results with the standard values given below:
Nominal play: 0.013 - 0.043 mm
Play at wear limit: 0.2 mm

If the results of the play measurements


described in points 1, 2, 3 and 4 exceed the
wear limit value, the affected parts must be
replaced.
Miscellaneous
- Check the driving gear of the rotor shaft and replace the entire assembly if it is slackened or turns in a
misaligned way.
- Push the plunger of the oil pressure governor valve through the housing hole and replace the entire
assembly if the plunger fails to return owing to a broken spring, etc. (Only for engines equipped with oil
heat exchanger).
- Check that the rotor shaft turns in a smooth and regular way when the driving gear is oper- ated.

0^ SECTION200 - ENGINE <L

--- DANGER
Do not use matches, cigarette lighters or
torches PUMP
YANMAR INJECTION as a light source on the machine
since it contains inflammable fluids.

1. Disconnect the fuel return hose (1) from the


injection pump.

How to bleed air from the fuel Circuit


2. Fill the system by operating the lever (1) on the
pump casing by hand.
Make sure that fuel flows from the pump return.

143
144
3. Disconnect the fuel hose (1) from one of the
injectors, operating as indicated in the figure.

4. Operate the starter motor and make sure that


the jet of fuel from the injector is adequate and
constant.
5. Connect the fix the hose (1).
6. Connect and fix the fuel return hose (1, fig.
142).
SECTION200 - ENGINE

INJECTION PUMP - OVERHAUL Demounting

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Proceed as follows:
1. Unscrew the fix fixing screws (2) and remove
the lower cover (3) of the injection pump (1) to
drain the lubricating oil from it.
2. Overturn the injection pump to drain off the
diesel fuel.

145
3. Operating as indicated in the figure, remove the
centrifugal weights from the regulator using the
puller (1) 008 MT MIS (mod. MIS- TRAL
AMERICA 40) or 009 MT MIS (models MISTRAL
AMERICA 45 and 50) (1).

To separate the regulator unit from the


injection pump, see page 110.

4. Remove the fuel pump (1) by loosening the fix-


ing nuts, as shown in the figure.

147
0^ SECTION200 - ENGINE <L

5. Unscrew the five fixing screws (2) and remove


the side cover (1) from the injection pump.

148
6. Using a wrench (1) as shown in the figure, turn
the camshaft (2) of the injection pump while
allowing the plunger guide to cover its maxi-
mum travel. Fit the tappet bearing bracket 010
MT MIS (3) between the lower plunger spring
retainer and the pump casing. Do this for each
plunger.

The specific tool 010 MT MIS is shown in


the figure on the right.

7. Remove the tab (3) from the camshaft (4) of the


injection pump.
150
8. Remove the bearing of the injection pump
camshaft in a horizontal direction, inserting a
screwdriver into each of the two grooves in the
surface on which the bearing support (1) is
mounted.

Make sure that the thread of the


injection pump camshaft does not
damage the seal.
2. Do not lose the adjuster seals and the
seal between the pump casing and
bearing support..

151
SECTION200 - ENGINE

9. Overturn the injection pump (1). Move all the


plunger guides towards this latter, then rest the
injection pump on one side. Turn the camshaft
(2) of the injection pump until the cam of each
cylinder touches the outer roller of the plunger
guide.
10. Place a plate against the camshaft end, on the
governor side. Tap on the plate and take out the
two bearings (3) of the camshaft and trans-
mission.

11. Remove the plunger guide retainers (1) using a


screwdriver, as shown in the figure.

12. Working as shown in the figure, and using the


handle of a hammer or a similar object, push
the plunger-guide upwards from the bottom of
the pump and take out the tappet (2) tool 010
MT MIS.

Take out the tappet (2) tool 010 MT MIS


with the greatest care. Make sure that the
plunger guide, plunger, etc., do not sud-
denly spring out. The plunger spring has
sufficient power to push the plunger out.

13. Remove the plunger-guide assembly (1).



Avoid holding the pump in a vertical posi- tion if
possible, as the plunger guide assembly
could drop to the ground. Rest the pump on
one side when the plunger-guide assembly is
being removed.

2LA0153

155
0^ SECTION200 - ENGINE <L
14. Take out the plunger (2), the spring (3) and the
lower retainer (1) of the spring from the lower
part of the injection pump.

Separate these parts for each cylinder.


EU3

156
15. Using a screwdriver, remove the retainer screw
(2) from the fuel governor pinion (1), as shown
in the figure.

1. Loosen the governor pinion (2) retainer


screw (1) to allow the part to be
removed from the adjuster sleeve (4).
Before loosening it, make sure that the
matching mark (3) on the pinion is
aligned with the one on the sleeve.
Make other marks if the mark is poorly
visible or not aligned. These marks will
be useful during the suc- cessive
injection timing phase.
2. Separate all these parts for each cylin-
der.

16. Remove the adjuster pinion (1), the sleeve (2)


and the upper retainer (3) of the plunger spring.

Separate these parts for each cylinder.

2LA0157

159
SECTION200 - ENGINE

17. Remove the retainer (1) of the adjuster rack (2)


and take this out, using a screwdriver, as shown
in the figure.
18. Slacken off the bolt (2) of the retainer (1) of the
delivery valve holder and remove it.

Make sure that the spring (2) and spacer


(1) on the rack (3) are not lost.

161

162
Q
SECTION200 - ENGINE

19. Remove the delivery valve assembly (1).

1. Take care to avoid losing the small


EU3 parts, such as the seal, the spring (3)
and the delivery valve pad (2).
2. Carefully separate the delivery valve
assembly of each cylinder.

2LA0161

163
20. Tyake out the plunger cylinder (1), allowing it to
pass through the upper part of the injection
pump.

Leave the cylinder and plunger together.

164

Assembly

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

1. Fit the plunger cylinder (1) back into the injec tion
pump, from the upper part.

Make sure that the retainer of the plunger


cylinder is correctly mounted in its hous-
ing with a key.

2LA0162

165
SECTION200 - ENGINE

Replace the seal and retention ring of the


delivery valve before re-assembling the
injection pump.

2LA0161

166

2. Insert the delivery valve assembly (1), the spring (3)


and the valve retainer through the upper part of the
injection pump as shown in the figure.

1. Make sure that the rack spring has


been mounted.

2. Make sure that the rack travel is regu-


lar.

3. Insert the rack (1) and tighten the relative retainer.

2LA0163

167
5. 4.
Insert the rack locking screw into the threaded hole of the
retainer.
Look at the injection pump from the bottom and align matching
mark S1 on the rack (1) with the S2 mark on the pinion (2).

2LA0164

168
0^ SECTION200 - ENGINE <L
Fit the sleeve so that the holes in its sur-
EU3 face point towards the retainer screw.
Meanwhile, align matching mark (Si) of the
sleeve (3) with that of the pinion.

6. Holding the pinion (2) with one hand so that the matching
mark is kept in the right position, fit on the sleeve (3) and
slightly tighten the pinion retainer screw (1).

7. Mount the upper retainer (1) of the plunger spring.


1. Mount the upper retainer (1) of the
El3 plunger spring.
2. Check again to make sure that the
rack moves in the correct way.

8. Mount the plunger spring.

9. Mount the lower retainer of the plunger spring on the top part

Do not mount the plunger in reverse, oth-


EU3 erwise the injection volume would increase
in an excessive way until it became
uncontrollable.

of the plunger itself. Align the matching mark on the plunger


side with the one on the adjuster sleeve and insert the plunger from the bottom of the injection pump using
tool 011 MT MIS.
SECTION200 - ENGINE

. Insert the plunger guide assembly at the bot-


tom of the injection pump. Push the plunger guide
upwards with the handle of a hammer or some
similar tool, then insert tappet bearing tool 010
MT MIS (1, fig. 173) between the lower spring
retainer and the body of the injec- tion pump.

1. Keep the retaining groove (2, fig. 172)


of the plunger guide pointing upwards
and align it with the corresponding hole
(1, fig. 172) of the plunger guide
retainer screw on the body of the
injection pump.
2. Check to make sure that the rack
moves freely. If this is not the case, it
means that the plunger spring is
interfering with some other part. In this
case, hold the spring in position with a
screwdriver.

3. Insert the normal adjuster ring and


tighten it at the same time when the
plunger guide assembly is being
replaced with a new one.

173
11. Make sure that the retainer groove (2, fig. 172)
of the plunger guide is positioned correctly.
Tighten the retainer screw (1) of the plunger
guide.

12. Position the bearings (2) on both ends of the


camshaft (1). Insert them by tapping them
lightly from the transmission side.

Overturn the injection pump. Move the


plunger guide towards the spring and fit the
camshaft into the injection pump.

SECTION200 - ENGINE

0^ <
13. Mount the retainer seal in the inner part of the
Before assembling, spread the camshaft and
bearing holder. Mount the bearing holder (1).
the retainer seal with oil to prevent them
from being damaged. 176
14. Fit
Camshaft floatthe camshaft.
the tab into 177
(all models) . . . . . . . (mm) 0.02 - 0.05
15. Using a wrench (1) as indicated in the figure, turn the
& camshaft (2) and remove the tappet bearing tools 010 MT
MIS (3).
5*16. Fix the injection pump on to a support. Using a plastic
hammer (5, fig. 175) tap in the end of the camshaft and
measure the float with tool
012 MT MIS.

Adjustment procedur
Remove the adjuster seal if the float is less. Add one or more
adjuster seals if the float is more.
Thickness of the adjuster seal: 0.5; 0.4; 0.3 and
0.15 mm.

17. Mount the side cover (1) of the injection pump.


178
SECTION200 - ENGINE

18. Mount the side cover (1) of the injection pump.


19. Tighten the spring holder of the delivery valve
to a 34.3 - 39.2 Nm torque value.

Tighten the spring holder of the deliv-


ery valve by hand as much as possi-
ble. If the bolt becomes difficult to turn
halfway through the operation, the seal
or the delivery valve could have slipped
out of position. Remove, adjust and
tighten again.
2. Do not tighten the valve holder too
much. Excessive tightening could cause
the rack to operate incorrectly.

180
20. Tighten the valve holder retainer stop (1) to a
2.9 Nm torque value.

Do not tighten the valve holder too much


as oil leaks could ensue.

21. Mount the fuel pump.

SECTION200 - ENGINE

0^ Thoroughly clean the parts before check- !


<
ing them. Take care to prevent the sliding
Do of
surfaces not use
the solvents
plunger, thetodelivery
clean the parts.
valve and Use
the
cleaning products
other components thatdamaged.
from being comply with the
standards in force.
Plunger inspection
1. Thoroughly clean the plunger (1). Replace the
plunger if its guide groove is scratched or dis-
coloured.
2. To test the plunger, tilt the plunger cylinder (1) at
an a angle of about 60 and check to make sure
that it slides backwards without friction. If it does,
the plunger can be considered efficient. Turn the
plunger and repeat the test several times. If the
plunger's reverse travel is too fast (or too slow), or
if it stops half way, repair it or replace the complete
assembly.
Delivery valve inspection
1. Replace the complete valve if the suction-thrust plate
or the delivery valve housing are scratched, notched, 183
worn or damage.
2. Plug the hole at the bottom of the delivery valve holder (2)
with a finger and maintain the housing unchanged. Fit the
delivery valve (1) into the valve holder. Remove the finger
and check to make sure that the valve trips backwards. If it
does, it is efficient, failing this it must be replaced.

2LA0178

185
1. Check to make sure that the sliding surfaces of SECTION200 - ENGINE
the plunger guide (1) are not worn too much.

Check whether the plunger cylinder housing


shows signs of irregular contact, burrs, traces of
gas leaks or other defects. If necessary repair or
replace the cylinder, otherwise the cir- culating
lubricating oil will dilute.
3. If the surface of the outer roller of the plunger
guide is worn or defective, it must be replaced.
4. If the circumference of the plunger guide and
the hole of the pin on the roller are worn or
defective, they must be replaced.
Replace the whole assembly if the plunger guide
5.
unit, the pin and roller are wavy.

Plunger guide, plunger cylinder inspection


Camshaft and bearing inspection
1. Camshaft
Check whether the surface of the camshaft (1) shows
signs of damage or wear and whether the spline housing
and the threads on both sides are warped. Replace the
camshaft if this is the case
2. Bearing
Replace the bearing if the surface of the tapered roller and outer
ring are damaged or worn.

The bearing must also be replaced when- !


ever the camshaft of the injection pump is
replaced.
Fuel regulating pinion and rack inspection
1. Make sure that the rack (1) is not warped, worn or bent in the point where the pinion meshes (2).
0^ SECTION200 - ENGINE <L

REGULATOR UNIT - OVERHAUL Demounting

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

1. Regulator housing removal.

Slacken off the self-locking nut (7) in


models equipped with torque regulator
spring assembly (8).

190
2. Remove the hex nut (1) of the control lever and
remove the lever from the shaft.
SECTION200 - ENGINE

3. Unscrew the fixing bolts (1) of the regulator housing (2).


Remove the regulator housing from the injection pump
(3) by lightly tapping on the housing with a plastic
mallet. Create a gap between the regulator housing and
the injection pump, moving only the mobile parts of the
regulator lever.
4. Push out the elastic fork of the regulator con- nection,
inserting a suitable pair of pliers (1) between the
2LA0185

192
injection pump and the regulator housing.
5. Separate the regulator (1) from the injection pump (2),
detaching it from the regulator housing and injection pump,
pushing the elastic fork away from the connection bracket of
the regulator with the rack.

2LA0186

193

194
2LA0187
0^ SECTION200 - ENGINE <L

6. Remove the return spring of the stop lever (1) from the
lever shaft (2).

7. Using an adequate pair of pliers (2), release the


regulator spring (1) from the tensioning lever (2) and
from the control lever shaft.

8. Remove the retainer of the regulator lever


shaft.
Remove the spring ring from both ends of the
regulator lever shaft.
197
9. Insert the rod (1) (diameter 8 mm or less)
into one of the ends of the regulator lever
shaft and tap on it until the retention ring
projects from the opposite side of the
regulator housing.
198
2LA0190

2LA0191
SECTION200 - ENGINE

10. Remove the O-ring (1) from the shaft (2) of the
regulator lever.

- Tap lightly on the end of the shaft and remove it.


11. Remove the bracket (1) that connects the reg- 2LA0193
200
ulator from the lever.
SECTION200 - ENGINE

0^ <
12.
The regulator assembly consists of the ! 203
regulator lever, the tensioning lever
and the torque adjuster spring assem-
bly. It normally need not be
demounted.

If necessary, take out the retainer lever, remove the stop


pin (1) of the retainer lever shaft and tap lightly
inside the regulator hous- ing.
SECTION200 - ENGINE

13. If necessary, take out the shaft of the regulator

1. Do not remove limiter unit FO from


! the regulator housing unless this is
strictly necessary.
2. For models with torsion springs, first
take out the blank nut, the self-lock-
ing nut and then the torsion spring
unit.

lever (1), tap lightly on the end of the shaft with a plastic mallet and remove the control lever itself.

14. Remove the sleeve (1) of the regulator at the


end of the injection pump camshaft by hand.
16. Remove the centrifugal weight assembly (1)
from the camshaft regulator using puller 008
MT MIS (mod. MISTRAL AMERICA 40) or 009
MT MIS (models MISTRAL AMERICA 45 and 50)
(1).

205
15. Fix the bearing support in a clamp in order to
hold the camshaft. Loosen the bearing nut of the
regulator with a spanner (2) a few turns.

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
When the tapered coupling detaches after
the nut has been removed, the centrifugal
weights of the regulator could spring out.
Q
SECTION200 - ENGINE

Assembly

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Check all parts after they have been demounted and


replace them if necessary. Clean all parts and set
them in order before re-assembling.
To make sure that the prescribed performances are
obtained, check that the assembly has been cor-
rectly adjusted after the re-assembly operations.
1. Fix the bearing support in a vice to hold the
camshaft of the injection pump in place. Fit the
centrifugal weight unit (1) of the regulator into
the tapering part at the end of the camshaft.
Mount the washer and tighten the nut that
supports the centrifugal weights of the regulator
to a 44.1 - 49.1 Nm torque value.

2. Open the centrifugal weight unit (1) of the reg -


ulator outwards and insert the sleeve (2) on to
the end of the camshaft.

Make sure that the sleeve is free to move


after it has been inserted.
SECTION200 - ENGINE

3. After having demounted the retainer lever,


mount the return spring on the lever itself, tap
the lever lightly with a plastic mallet in order to
bed it and then tighten the stop pin.

209

4. After having removed the control lever shaft,


insert the shaft and washer inside the regulator
housing using an appropriate tool.
5. If the regulator has been demounted, insert the
spring pin (1) by tapping it lightly.

210

6. Mount the regulator lever assembly (1) on to its


connection bracket.
Make sure that the fixing holes of the regu-
lator connecting bracket are the right ones
and that the regulator is fitted in the correct
position.
Check to make sure that the connection
bracket of the regulator moves freely.
0^ SECTION200 - ENGINE <L

7. Insert the regulator lever shaft (1) assembly into the


regulator housing and tap it lightly until the retention
ring groove projects from the opposite side of the
housing.
First mount the retention ring on the side on which it
strikes.
Remember to mount the washer (1) on both
ends of the regulator lever.

212
SECTION200 - ENGINE

8. After having mounted the retention ring (1), tap on


the shaft (2) of the regulator lever in the opposite
direction and mount the spring rings into the grooves
on both ends.
After having mounted the regulator lever unit, make
sure that its movement is regu- lar.

214

9. Mount the return spring (1) of the retainer lever


on the end of the shaft (2) of the gover- nor
lever.

10. Couple the spring (1) of the regulator on to the shaft


of the control lever and on to the tension- ing one (2)
using an appropriate pair of pliers (3).
0^ <22
SECTION200 - ENGINE

2LA0209
11. Keep the regulator connection adjuster bracket (1) as 217
far as possible from the surface on which the regulator
housing is mounted. Insert the pin of the connection
bracket into the rack pin hole and mount the spring pin.
12. Mount the regulator housing (2) on to the injection
pump (1) and meanwhile tap lightly on it with a plastic
hammer. Tighten the fixing screw (3).
13. Fit on the cover of the regulator housing.
For models equipped with secondary spring for
the idling rate, insert the spring and adjuster
rod on to the adjuster bolt of the regulator
housing cover.

218

Tighten the nut in a temporary way if the


torque regulator spring assembly has been
removed. The nut must be ade- quately
tightened after the adjustments have been
made.

14. Insert the control lever into the corresponding


shaft and tighten the nut (1).

Move the control lever backwards and for-


EU3 wards to make sure that the movement is
regular all along the connection bracket.
SECTION200 - ENGINE

Checking the centrifugal weights of the regulator


Examine the centrifugal weight assembly (1) to
make sure that it is in a good condition and func-
tional. It should be replaced in the following cases:
- if the centrifugal weights fail to open or close in
a regular way;
- if the surface on which the centrifugal weights
contact the sleeve is excessively worn;
- if the centrifugal weight support and pin is worn
or the caulking has loosened;
- if the retainer of the centrifugal weight support
is excessively worn.

220

Key:
1. Pin
2. Centrifugal weight of the regulator
3. Support of the centrifugal weights of the regulator

221
Regulator sleeve inspection
Examine the regulator sleeve to make sure that it is
in a good condition and functional. It should be
replaced in the following cases:
- if the surface on which the sleeve contacts the
centrifugal weights is worn;
- if the surface on which the sleeve contacts the thrust
pin is worn;
- if the sleeve fails to move smoothly on the cam- shaft
of the injection pump (e.g. owing to wear on the
inner diameter of the sleeve itself);
- if the retainer of the centrifugal weight support is
excessively worn.
Key:
222
1. Contact surface of the thrust pin
2. Contact surface of the centrifugal weights of the
regulator
3. Inner sleeve diameter

Regulator lever shaft assembly


inspection demount and replace the thrust pin only.
1. Measure the play between the shaft (2) of the
regulator lever and the bush (1) and replace if
the value is near to the wear limit.

Normal Play Wear


dimension normal limit
Check the condition of the (mm) thrust pin's contact
(mm)
surface. If there are signs of wear or scorching,
Outer diameter
remove the pin of the spring in order to
of the 7.986 -
Check whether the connection components show
7.995
regulator lever
signs of warping or twisting0.065 - lead
which could 0.5 to
shaft
faulty operation. Replace any0.124
defective parts.
Spring inspection
If necessary, replace the lever of the regu lator,
Float
Inner
Check the on the (1)
bush upper
8.060part of the regulator
the- the lever
thespring
diameter tensioningoflever, regulator
bush, and the
the thrustother
pin
shaft
springs.and =
Replace 0.4
themmm.if
8.110 they are broken, rusted or
the torque adjuster spring, considering
yielding.them a complete assembly.
2.
3. 224
SECTION200 - ENGINE SECTION200 - ENGINE

Checking the torque adjuster spring assembly


1. Check the sliding surfaces of the thrust pin (1) and replace it
if it is defective.
2. Replace the torque adjuster spring assembly (2) if the spring
is broken.

Checking the torsion spring assembly


1. Check the wear at the top of the piston (2) and the contact
surface. Replace the parts if they appear to be worn or defective.

2. Replace the assembly if the torsion spring (1) is broken.


2LA0218

226
SECTION 300

CLUTCH
SECTION300 - CLUTCH
INDEX
Q
Description Page

GENERAL SPECIFICATIONS OF THE LX 9"/9" CLUTCH.................................................................... 300-3

DRIVING TORQUE VALUES........................................................................................................... 300-3

SPECIFIC EQUIPMENT................................................................................................................. 300-4

SECTIONS................................................................................................................................. 300-5

TROUBLESHOOTING FOR THE CLUTCH ASSEMBLY...................................................................... 300-6

WHERE THE SEALANT IS APPLIED FORTHE CLUTCH HOUSING ON THE TRANSMISSION HOUSING . 300-7

CLUTCH SPLITTING-REMOUNTING................................................................................................. 300-8


Splitting.......................................................................................................................... 300-8
Remounting.................................................................................................................... 300-16

CONTROL ADJUSTMENT
GEARSHIFT CLUTCH ................................................................................................................. 300-18

CONTROL ADJUSTMENT
POWER TAKE-OFF CLUTCH ........................................................................................................ 300-19

300-2 P/N3676163M1 Edition07-2004


SECTION300 - CLUTCH
GENERAL SPECIFICATIONS OF THE LX 9"/9" CLUTCH
Type
unit with two single-plate dry clutch
assemblies
Control
mechanical: pedal operated for the
gearshift clutch; with hand lever for the
PTO clutch
Engaging and disengaging mechanism single Belleville washer

Type of coating on the driven disc of the gearshift clutch organic


Type of coating on the driven disc of the PTO clutch organic

SPECIFIC
DRIVING TORQUE
EQUIPMENT
VALUES
Code PARTS TO TORQUE Description
Thread Driving torque values

Nm kgm
001 FRI MIS Clutch assembly centring tool
Screws fixing
0029"/9"
FRI MIS
clutch to the flywheel
Clutch assembly adjuster tool M 8 x 1.25 20 - 25 2 - 2.5

Nuts fixing 003 FRIhousing


clutch MIS Clutch assembly adjuster journal M 12 x 1.25
to the engine 117 - 129 11.6 - 13.1

P/N3676163M1 Edition 07-2004 3003


SECTION300 - CLUTCH

SECTIONS

1. PTO clutch control lever 7. Belleville washer


2. Gearshift clutch friction disc 8. Pressure plate
3. Gearshift clutch control lever 9. PTO clutch friction disc
4. Nut 10. Nut to adjust height of PTO clutch control
5. Screw to adjust the height of the gearshift clutch dis- lever
engaging lever 11. Rod
6. Pressure plate
12. Clutch unit
0^ SECTION300 - CLUTCH 2
TROUBLESHOOTING FOR THE CLUTCH ASSEMBLY

Faults Possible causes Remedies

The clutch slips 1. Wear on the discs (2 and 9, fig Compare with the values given in the
1) of the pressure plates and indicated pages. Replace excessively
flywheel. worn parts and adjust the levers and
clutch controls.
Replace the Belleville washer.
Belleville washer (7, fig. 1)
2.
stretched or damaged.
3. Oil or grease on the disc fric- Replace the discs. Eliminate the cause
tion material (2 and 9, fig. 1). that led to the presence of lubricant in
the clutch housing and thoroughly clean
the friction surfaces.

The clutch jerks 1. External controls hardened. Check the hinging and lubricate.

Replace the disc and adjust the clutch


2. Warped clutch plate (2, fig. 1).
lever.
3. Oil or grease on the disc fric- Replace the discs. Eliminate the cause
tion surfaces (2 and 9, fig. 1). that led to the presence of lubricant in
the clutch housing and thoroughly clean
the friction surfaces.

The clutch fails to disengage and Warped clutch plates (2 and 9, Replace the discs (make the adjust-
1.
drags fig. 1). ments).
External controls seized.
Check, replace the faulty parts and
2.
lubricate.

3. Badly adjusted controls. Adjust the controls (see page18).


Worn thrust bearings. Replace the bearing
Clutch noisy when engaged and/or
1.
disengaged
Replace the plate.
Clutch plate (2, fig. 1) with faulty
2.
springs.

Clutch pedal too hard to operate 1. External controls hardened. Check the hinging and lubricate.

2. Hardened pedal hinging. Check the hinging and lubricate.

SECTION300 - CLUTCH

WHERE THE SEALANT IS APPLIED FOR THE CLUTCH HOUSING ON THE


TRANSMISSION HOUSING

2LA0726 2
The types of sealant to apply are indicated in section 100.

0^ SECTION300 - CLUTCH 2
CLUTCH SPLITTING-

DANGER
Lift and handle all heavy parts with lifting
equipment of an adequate capacity.
Make sure that the units of parts are sup-
ported by appropriately sized harness and
hooks. Make sure that there are no
bystanders near the load being lifted.

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

REMOUNTING Splitting
Proceed as follows:
1. Unscrew the screw (1) and remove the bonnet.
2. Unscrew the fixing screws (1) and remove the side panels (2) (from both sides).
3. Loosen the clamp bolt (1) and disconnect the
negative battery wire.

4. Fix the rear safety frame (2) to a hoist (1) and


tighten the belt.

5. Unscrew the fixing screws (1) and remove the


rear safety frame (2) by means of a hoist.

6. Detach the pedal accelerator wire (1) and the


hand throttle wire (2).

8
SECTION300 - CLUTCH

7. Using a pin driver, remove the spring pin (1) and


take out the gear lever (2).

8. Unscrew the fixing screws (1) and remove the


guard from the controls (2) on the right-hand
side of the seat.

9. Unscrew the fixing screws (1) and remove the


guard from the controls (2) on the left-hand side
of the driver's position.

10. Unscrew the fixing screws (1) and remove


the seat (2).

12

P/N3676163M1 Edition 07-2004 300-11


SECTION300 - CLUTCH

11. Remove the knob (1) that regulates the sensi-


tivity of the power lift and the 4WD engaging
lever (2).

12. Disconnect the hydraulic pipe unions (1) from the


auxiliary control valve unit.

13. Disconnect the flexible cable (1) from the control


lever (2) of the fork that disengages the gearshift
clutch.

14. Disconnect the flexible cable (1) from the control


lever (2) of the fork that disengages the PTO clutch.

300-12 P/N3676163M1 Edition07-2004


SECTION300 - CLUTCH

15. Disconnect the flexible cable (1) that Controls the


brake (on both sides).

16. Disconnect the flexible cable (1) that controls the


parking brake.

17. Disconnect the flexible cable (1) that controls PTO


engagement, PTO speed selection (2) and the rigid
rod that engages the 4WD (3).

18. Disconnect the flexible cable (1) that controls


the range selection function.

20

P/N3676163M1 Edition 07-2004 300-13


SECTION300 - CLUTCH

19. Detach the rods (1) that control the power lift
valve system.
21. Unscrew the rear fixing bolts (1) of the flexible
support of the platform in the zone where the
side final drive is installed on both sides of the
tractor.

20. Unscrew the front fixing


form in the zone where
sides of the tractor.

22. Detach the front ballast (if installed), using a hoist


and two steel ropes.
23. Remove the oil from the gearbox - rear trans-
mission, by unscrewing the plug under the gearbox
itself.

Old oil must be disposed of in compliance


with the current laws in merit.

300-14 P/N3676163M1 Edition07-2004


SECTION300 - CLUTCH SECTION 300 - CLUTCH

24. Remove the complete platform (2) using a hoist


(1).

25. Using a pin driver, remove the spring pin (1),


slide the coupling sleeve (2) and remove the
4WD shaft (3) (these operations must be car-
ried out on both ends of the shaft).

30

26. Disconnect the hydraulic pipe unions (1) from the diff
lock solenoid valve (2) and disconnect the front diff
lock hose (3).

27. Loosen the closing clamps (1) and remove the


transmission lubricating oil inlet hose (2).
28. Disconnect the union (1) of the oil delivery hose from
the pump to the power lift valve system pump and to
the auxiliary control valve.

29. Place two fixed stands (1), one under the engine oil sump and the other under the fromt part of the clutch
housing. Fix two chains (2) to the rear hooks on the engine and to the hoist and pull on this latter.
30. Block the front axle with a chock to prevent the engine from swinging, then unscrew the bolts (3) that fix the
clutch housing to the engine and split the clutch housing from the engine.

P/N3676163M1 Edition 07-2004 300-15


31. Using tool 001 FRI MIS (1), unscrew the fix-
ing screws (2) and remove the clutch (3).

31

300-16 P/N3676163M1 Edition07-2004


Q
SECTION300 - CLUTCH

Remounting
Fit the engine back on to the clutch housing bear- ing the following recommendations in mind:

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
Apply the driving torques listed on page 3.

Before the engine is fitted back on to the clutch housing, thoroughly clean and degrease the surfaces to be
coupled and apply a strip of seal- ant with a diameter of about 2 mm, following the line shown on page 7.
7.

Fix the clutch back on to the flywheel using tool 001 FRI MIS.

Using tool 002 FRI MIS and cross 003 FRI MIS , adjust the clutch levers in order to obtain
1. 1 mm play between the end of the actual lever and the cross.
- Using a hoist, couple the engine-front axle assembly and fix it in place.

- Connect the hose that delivers oil to the power lift valve system and to the auxiliary control valve.

- Connect the gearbox lubricating oil hose.


- Connect the hydraulic hoses of the front and rear differential locks.

- Remount the 4WD shaft.


- Screw on the plug that drains the oil from the rear transmission oil and fill with oil (see sec- tion 100).

- Position and fix the platform.


- Position and fix the rear safety frame.
- Connect the control rods of the power lift valve system.

- Connect the flexible cable that controls the range selection function.

- Connect the 4WD engaging rod.


SECTION300 - CLUTCH

- Connect the flexible cable that selects the PTO speed.

- Connect the flexible cable that engages the PTO.

- Connect the brake cables.


- Connect the flexible cable of the PTO clutch control lever.

- Connect the flexible cable of the gearshift clutch control lever.

- Position and fix the lifting valve system.

- Position and fix the seat.

- Connect the accelerator control cables.

- Position and fix the rear safety frame.

- Fix the side panels of the engine in place.

- Fix the bonnet in place.


0^ SECTION300 - CLUTCH <L
CONTROL ADJUSTMENT
GEARSHIFT CLUTCH

2. Loosen the check nut (1).

3. Remove the fixing pin (1) and disconnect the fork (2)
from the clutch control lever (3). Tighten or loosen
the fork in order to adjust the clutch control.

4. Re-position the fork (2, fig. 33) and the fixing pin (1,
fig. 33).
5. Make sure that the clutch pedal (1) travel is between
15 and 25 mm.
6. Lock the check nut (1, fig. 32).
SECTION300 - CLUTCH SECTION300 - CLUTCH

CONTROL ADJUSTMENT POWER


TAKE-OFF CLUTCH

1. Loosen the check nut (1).


Tighten or loosen the
adjuster (2) to regulate the
clutch control.

2. Make sure that the idle


travel of the clutch
pedal (1) is between
25 and 30 mm.
3. Lock the check nut (1, fig.
35).

36
SECTION 400
(12 + 12) AND (16 + 16) MECHANICAL GEARBOX

INDEX
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX
<
Description

MAIN SPECIFICATIONS OF THE GEARBOX AND FINAL DRIVE .......................................................

400-3

MAIN SPECIFICATIONS OF REVERSE SHUTTLE ...........................................................................


SECTION 400

MAIN SPECIFICATIONS OF THE SUPPLEMENTARY FINAL DRIVE (16 + 16

VERSION)..............................................................................................................................

400-3

DRIVING TORQUE VALUES.......................................................................................................

SECTIONS.............................................................................................................................

DESCRIPTION AND OPERATION................................................................................................


Gearbox and reverse shuttle ..........................................................................................
SECTION 400

Supplementary final drive (16 + 16 version).....................................................................

TROUBLESHOOTING FOR THE GEARBOX, FINAL DRIVE AND REVERSE

SHUTTLE 400-8

TROUBLESHOOTING FOR THE SUPPLEMENTARY FINAL DRIVE (16-16

VERSION) 400-9
SECTION 400

WHERE THE SEALANT IS APPLIED FOR THE GEARBOX-REAR

TRANSMISSION HOUSING

400-10

GEARBOX TRANSMISSION HOUSING SPLITTING-REMOUNTING ....................................................


Splitting.......................................................................................................................
Remounting..................................................................................................................

GEARBOX TRANSMISSION HOUSING - OVERHAUL.......................................................................


Demounting..................................................................................................................
Assembly......................................................................................................................
SECTION 400
Main shaft float adjustment.............................................................................................
Reverse shuttle gear float adjustment ..............................................................................

CLUTCH HOUSING - OVERHAUL................................................................................................


Demounting..................................................................................................................
Assembly......................................................................................................................
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

MAIN SPECIFICATIONS OF THE GEARBOX AND FINAL DRIVE


Gearbox ................................................................................. with 4 ratios, infinitely meshed
gears and synchronizers for all
speeds

Type of gears........................................................................... with helical toothing

cascade type with 3 speed ranges


Final drive............................................................................... . . . (mm)
for a total 12 speeds.

- Type of gears........................................................................ . . . (mm) with straight toothing


Gearbox and final drive controls................................................. . . . (mm)
independent, with lever installed
on the operator's right, under the
steering wheel
Thickness of main shaft adjuster ring (SP2, fig. 3)......................... . . . (mm)
1.00 - 1.10 - 1.20 - 1.30 - 1.40 -
1.50 - 1.60 - 1.70 - 1.80

Thickness of reverse shuttle gear adjuster ring (SP^ fig. 2)........... . . . (mm)
1.00 - 1.10 - 1.20 - 1.30 - 1.40 -
1.50 - 1.60 - 1.70 - 1.80

MAIN SPECIFICATIONS OF REVERSE SHUTTLE


Type ............................................................................................ mechanical with straight teeth,
installed between the main
clutch and gearbox.

Control......................................................................................... by means of dedicated lever on


the operator's left

MAIN SPECIFICATIONS OF THE SUPPLEMENTARY FINAL DRIVE (16 + 16 VERSION)

Type ............................................................................................ cascade with straight teeth,


installed between the gearbox
and bevel gear pair. Obtains 16
forward and 16
reverse speeds

Control ........................................................................................ by means of dedicated lever on


the operator's right

SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

DRIVING TORQUE VALUES <


1
Driving torque values
PARTS TO TORQUE Thread
Nm kgm

Screw fixing the clutch housing to the gearbox-rear transmission


M 12 x 1.25 117 - 129 11.9 - 13.1
housing (C1)...................................................................

Gearbox housing cover fixing


P/N3676163M1 screws..................................
Edition 07-2004 - 43 - 51 4.4 - 5.2 4003

Pressure switches............................................................ - 51 - 72 5.2 - 7.3

2LA0864
P/N3676163M1 Edition 07-2004 4003
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

SECTIONS
<

2
Longitudinal section of the clutch housing
Thi Adjuster shims. 5. Reverse shuttle engaging unit.
1. Clutch 6. Shaft for gearbox disc disengaging fork.
2. Clutch housing. 7. Shaft for PTO disc disengaging fork.
3. 4WD engaging unit. 8. Gearshift control shaft.
4. Reverse shuttle unit. 9. Spring ring.
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

Longitudinal section of the gearbox and range reduction unit (12 + 12)

Sh2 Adjuster shims. 5. Range selector.


1. Ball bearings. 6. Gearbox.
2. Transmission shaft. 7. Upper shaft.
3. 1st and 2nd gear synchro-mesh unit. 8. Main shaft.
4. 3rd and 4th gear synchro-mesh unit. 9. Bevel pinion.
<n
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

P/N3676163M1 Edition 07-2004 400-7


TROUBLESHOOTING FOR THE GEARBOX, FINAL DRIVE AND REVERSE SHUTTLE
Faults Possible causes Remedies

Transmission rods and levers incorrectly Adjust correctly.


The gearbox, final drive or reverse
shuttle disengage spontaneously. adjusted.
DESCRIPTION AND OPERATION.
Faulty control rod retention springs. Replace the springs.

Gearbox and reverse shuttle


The gearbox is equipped with 3. helical
Faultytoothed
synchromesh
infi- engaging teeth
version), Remove
or 16 the 16 gearbox-transmission
forward and reverse speeds (16 +
nitely meshed gears controlled by two or engaging
synchro- sleeves.
16 version). housing and replace
It is controlled by athe synchromesh
dedicated lever
mesh units. It provides 4 speeds. unitsoperator's
installed on the or engagingleftsleeves.
under the steering
The range reduction unit isIncomplete
the cascade wheel.
type with travel.
engagement Eliminate the causes and adjust for
infinitely meshed straight toothed gears. The reverse complete
shuttle consists
travel. of a straight toothed
The reduction unit provides: 3 forward speed ranges gear. The reverse shuttle is engaged by means of a
The gearbox, final drive or reverse
Transmission rods and levers incorrectly
synchromesh. Adjust correctly.
(12 + 12 version) or 4 speed ranges (16 + 16
shuttle are difficult to engage.
version). adjusted. The reverse shuttle is installed inside the clutch
Transmission rods and housing, between
Check the actual clutch
the hinging itself and the
and lubricate.
The gearbox and range reduction unit are control led levers hardened
and/or gearbox.
by two independent levers installed on seized.
the operator's
The assembly is lubricated by the oil in the gear-
right under the steering wheel.
The central clutch drags. See sect. 18.
box-rear transmission housing.
The reverse shuttle is a mechanical device that pro-
Faulty synchromesh units or engaging Remove the gearbox-transmission
vides: 12 forward and 12 reverse speeds (12 + 12
sleeves. housing and replace the synchromesh
units or engaging sleeves.
Supplementary final drive (16 + 16 version)
The supplementary final drive is a mechanical
5. The device
internal controls do not slide Overhaul the controls.
that provides 16 forward and 16smoothly.
reverse speeds: The supplementary final drive is installed prior to the
rods, forks and sleeves.
gearbox and is controlled by a dedicated lever on the
The supplementary final drive only becomes opera-
platform, to the operator's right.
tive infinal
The gearbox, the drive
slow ranges.
or reverse Some internal component is Remove the gearbox-transmission
shuttle operate in a noisy way. worn or defective. housing and replace the faulty parts.

<n SECTION 400 - (12 SECTION


+ 12) AND (16
400 + 16)
- (12 MECHANICAL
+ 12) AND (16 +GEARBOX
16) MECHANICAL GEARBOX

TROUBLESHOOTING FOR THE SUPPLEMENTARY FINAL DRIVE (16-16 VERSION)

Faults Possible causes Remedies

The supplementary final drive dis- 1. External transmission rods and Adjust correctly.
engages spontaneously. levers incorrectly adjusted.

2. Incomplete engagement Eliminate the causes and adjust for


travel. complete travel.

The supplementary final drive is dif- 1. External rods and levers incor- Adjust correctly.
ficult to engage. rectly adjusted.

2. External rods and levers hard- Check the hinging and lubricate.
ened and/or seized.

3. The central clutch drags. See sect. 18.

4. The internal controls do not Overhaul the controls.


slide smoothly. rods, forks and
sleeves.

The supplementary final drive oper- 1. Some internal component is Remove the clutch housing and
ates in a noisy way. worn or defective. replace the faulty parts.

WHERE THE SEALANT IS APPLIED FOR THE GEARBOX-REAR TRANSMISSION HOUSING

400-8 P/N3676163M1 Edition07-2004


2LA0275

4
The types of sealant to apply are indicated in section 100.

P/N3676163M1 Edition 07-2004 400-9


SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

GEARBOX TRANSMISSION HOUSING SPLITTING-REMOUNTING

Splitting
Proceed as follows:
DANGER
Lift and handle all heavy parts with lifting
equipment of an adequate capacity.
Make sure that the units or parts are sup-
ported by appropriately sized harness and
hooks.
Make sure that there are no bystanders
near the load being lifted.

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

1. Split the clutch (see section 300 up to point 29).


2. Unscrew the fixing screws (1) (2) and remove the cover (3) (4) of the gearbox.

3. Remove the spring ring (1) and take out the reverse
gear (2).
4. Unscrew the lubrication union (1) of the main shaft.

5. Remove the spring ring (1) and take out the PTO
engaging lever (2).

6. Remove the spring ring (1) in order to remove the


4WD engaging lever (2).

7. Remove the spring ring (1) and take out the range
selection lever (2).
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

8. Unscrew the fixing screws and split the clutch


housing (1) from the gearbox - rear transmis- sion
housing (2).

Remounting
Comply with the following recommendations when remounting the gearbox-rear transmission housing:

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
- Consult figures 2 and 3 in order to position the various parts correctly.
- Before remounting the housings, supports and covers, thoroughly clean and degrease the cou- pling
surfaces and apply a strip of sealant about 2 mm in diameter as indicated in figure 4.
- Apply the driving torques listed on page 4.
- Fit the clutch housing back on to the gearbox- rear transmission housing.
- Mount the range selection lever, the 4WD engaging lever and the PTO engaging lever.
- Mount the union of the main shaft lubrication hose.
- Mount the reverse gear and relative spring ring.
- Position and fix the gearbox covers.
- Re-connect the clutch (see section 300).
<n
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

GEARBOX TRANSMISSION HOUSING -


OVERHAUL

Demounting
Proceed as follows:
WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

1. Fix the gearbox-transmission housing to a fixed


stand.
2. Unscrew the fixing screws (1) and remove the
gear lever assembly (2).

13
3. Detach the power lift valve gear transmission rods (1).
4. Unscrew the hydraulic hose union (1) of the valve system.
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

5. Unscrew the fixing screws (1) and remove the valve


system (2) of the power lift.

6. Take out the pin (1) that connects the cylinders to the
lifting links. Unscrew the bolt (2) that fixes the power lift
cover.

7. Fix the hoist chains (1) to the power lift cover (2) and
remove it.

8. Remove the control shaft of the rear PTO (1).

18
9. Unscrew the closing plugs (1) and recover the retainer
balls and springs of the rods.

10. Using a pin driver, remove the spring pins (1)


that hold the gear engaging forks (2) in place.

20

11. Unscrew the lock nuts (1), take out the rods (2) and
recover the synchromesh forks (3).

12. Remove the spring ring (1) of the main shaft.


Remove the lubrication collar (2) and recover the
spacer and adjuster shims.

22
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

13. Take out the front part of the main shaft (1) and
recover the bronze bush (2).

14. Remove the spring ring (1) that holds the upper
shaft.

24

15. Retract the upper shaft, recover the synchro-


mesh (1) of the 3rd and 4th gear and the
engaging fork (2) of the 1st and 2nd gear.

25

16. Remove the spring ring (1) and take out the PTO gear
(2). Recover the washer and bearing.
17. Remove the front spring ring (1).

18. Take out the rear part of the main shaft (1) and
recover its components (2). 28

19. Recover the fork (1) that engages the ranges.

20. Remove the spring ring (1) that holds the driven
gear of the ranges.

30
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

21. Unscrew the pinion locking nut (1) and remove


the gear (2).

22. Push the pinion (1) towards the rear part of the
gearbox-transmission housing using an ade-
quate tool.

23. Take out the pinion (1) and recover the speed
range gears (2).
33

24. Remove the spring ring (1) that holds the 1st and
2nd gear synchromesh.

400-18 P/N3676163M1 Edition07-2004


34

P/N3676163M1 Edition 07-2004 400-19


<n
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

25. Push the transmission shaft (1) towards the rear part of
the gearbox-transmission housing using an adequate
tool.

26. Remove the transmission shaft (1) and recover the 1st
and 2nd speed gears (3) and synchro- mesh.

27. Remove the spring ring (1) that holds the


transmission gear of the slow ranges.

28. Retract the gear (3) in order to remove the


spring ring (1) that holds the bearing in place.
Take out the bearing (2) and recover the slow
speed range transmission gear.

38
40
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

29. Unscrew the locking bolt (1) of the


supplemen- tary final drive engaging
fork (2).

30. Remove the spring ring (1) that holds


the shaft that supports the
supplementary final drive gear and
unscrew the retention screw (2) of the
rear bearings.

31. Remove all the supplementary final drive


com- ponents (1) from the gearbox-
transmission housing.
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX <n

Comply with the following recommendations


when remounting the gearbox-transmission 41
housing:

Assembly

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Consult figures 2 and 3 in order to position the


various parts correctly.
Before remounting the housings, supports and
covers, thoroughly clean and degrease the cou-
pling surfaces and apply a strip of sealant about
2 mm in diameter as indicated in figure 4.
Apply the driving torques listed on page 4.
Mount the supplementary final drive compo-
nents and relative engaging fork.
Mount the transmission gear of the slow speed
ranges along with the relative spring retention
rings.
Mount the transmission shaft, 1st and 2nd speed
synchromesh and the relative gears. Mount the
pinion with the speed gears.
Lock the pinion nut (see Section 500, Bevel gear
pair adjustments, for the relative adjust- ments
required).
Mount the spring ring that holds the driven gear
of the ranges.
Position the fork that engages the ranges. Mount
the rear part of the main shaft along with the
relative components and the front spring ring.
Mount the PTO gear with the washer, the bear-
ing and spring ring.
Mount the 3rd and 4th speed synchromesh and
the engaging fork of the 1st and 2nd gear.
Mount the spring ring of the upper shaft.
Mount the front part of the main shaft with the
relative bronze bush.
- Mount the adjuster shims, the spacer, the lubri-
cation collar and the spring ring of the main
shaft.
- Mount the rods with the relative control forks.
- Mount the closing plugs with the retainer balls and
springs of the rods.
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

- Mount the shaft of the rear PTO drive.


- Position and fix the cover of the power lift.
- Connect the cylinders to the lifting links, using the relative connection plugs.
- Position and fix the valve system to the gearbox transmission housing.
- Connect the hydraulic hose of the valve system.
- Connect the power lift valve gear transmission rods.
- Remove the gearbox-transmission housing from the stand.
<n
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

Proceed as follows:
1. Using a depth micrometer, measure dimension
^E37 (Li) between the bearing and the front plane of

Main shaft float adjustment

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

42

Make sure that, once mounted, the main ! the gearbox-transmission housing.
shaft has a 0.1 mm float to ensure that it 2. Measure thickness (L2) of the spacer (1) with a
operates correctly.
micrometer.
4. The adjuster shim (Sh2, page 5) to mount on
the main shaft will be given by:
Sh2 = (L1 + L3 + 0.1) - L2
where
L1 = dimension measured
L2 = dimension measured
L3 = dimension measured
1. 3. Using a depth micrometer, measure depth (L3) of
the seat of the spacer on the clutch housing.

43
1 = operating play of the main shaft.
Round off to the lower figure.
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX
WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Once mounted, the reverse shuttle gear !


must have a 0.3 - 0.4 mm float to ensure that it
operates correctly.

Proceed as follows:
Mi
1 Using a depth micrometer, measure dimension
. (M1) between the front plane of the gearbox-
transmission housing and the spring ring
mounted on the main shaft.

2.

Reverse shuttle gear float adjustment


Using a depth micrometer, measure dimension (M 2) between the rear plane of the clutch housing and the
reverse shuttle gear (1).

3.
The adjuster shim (Sh1, page 4) to mount on the main shaft and the reverse shuttle gear will be given by:
Sh = M2 + (0.3 - 0.4) - M
where
M1 = dimension measured
M2 = dimension measured
0.3 - 0.4 = operating play of the synchro-
mesh gear.
Round off to the lower figure.
<n
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

Proceed as follows:
2. Split the gearbox-transmission housing.
3.
CLUTCH HOUSING - OVERHAUL

Demounting

WARNING
3.
Handle all parts with great care. Do not put
Fix your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

the clutch housing to a rotating stand. 2LA0308


44

4. Remove the retention springs (1) of the thrust


bearing (2).

45

48
5. Remove the thrust bearing (1).
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

6. Unscrew the locking plug (1) and the fixing screws


(2), and remove the cover (3).

7. Unscrew the locking screw (1) of the reverse shuttle


engaging fork (2).

8. Take out the rod (1) and recover the engaging fork
(2).

52

9. Remove the reverse shuttle synchromesh (1).


SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

10. Remove the bearing (1) using a puller (2).

11. Remove the front and rear spring rings (1) of


the reverse shaft. 54

12. Remove the sealing plug (1) by levering with a


suitable tool.

13. Remove the spring ring (1) that holds the bear-
ing of the reverse shaft.
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

14. Remove the reverse shaft (1) and recover the gear
(2).

15. Remove the spring ring (1) that holds the driven
shaft.

16. Remove the driven shaft (1) complete with the


relative bearing.

17. Remove the retention ring (1) by levering with a


suitable tool. Remove the spring ring (1) that holds
the PTO shaft and allow the shaft itself to move
forward, using a suitable tool.
<n
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

18. Remove the bearing (2) of the 4WD shaft using a puller 61
(1).
19. Remove the spring ring (1) and take the 4WD engaging
lever (2) out of the clutch housing.

20. Use an aluminium bar (1) to oppose the move-


ment of the gear (3). Remove the 4WD shaft
and the relative gear (3) with a suitable tool
(2).

SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

Assem
bly

Remount the clutch housing bearing the following


recommendations in mind:

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
- Consult figures 2 and 3 in order to position the various parts correctly.
- Mount the 4WD shaft and the relative gear.
- Insert the 4WD engaging lever and lock it in place with the relative spring ring.
- Mount the bearing of the 4WD shaft.
- Mount the driven shaft with the relative bearing and spring retention ring.
- Mount the reverse shaft with the relative gear and spring retention ring.
- Mount a new retention plug.
- Mount the front bearing of the reverse gear along with the relative spring retention rings.
- Insert the reverse shuttle synchromesh.
- Mount the engaging fork of the reverse shuttle, lock the sliding rod and insert the retention plugs.
- Mount the thrust bearing with the relative retention springs.
- Remove the housing from the rotating stand.
- Remount the gearbox-transmission housing.
<n
SECTION 400 - (12 + 12) AND (16 + 16) MECHANICAL GEARBOX

REAR DIFFERENTIAL AXLE

40030 P/N3676163M1 Edition07-2004


SECTION500 - REAR DIFFERENTIAL AXLE

INDEX
Q
Description Page

MAIN SPECIFICATIONS OF THE BEVEL GEAR PAIR AND DIFFERENTIAL............................................... 500-3

DRIVING TORQUE VALUES........................................................................................................... 500-4

SECTIONS.................................................................................................................................. 500-7

DESCRIPTION AND OPERATION.................................................................................................... 500-9

TROUBLESHOOTING FOR THE BEVEL GEAR PAIR AND DIFFERENTIAL................................................. 500-9

TROUBLESHOOTING FOR THE SIDE FINAL DRIVES ......................................................................... 500-9

WHERE THE SEALANT IS APPLIED FOR THE GEARBOX-REAR TRANSMISSION HOUSING...................... 500-10

REAR TRANSMISSION HOUSING - OVERHAUL .............................................................................. 500-11


Demounting................................................................................................................... 500-11
Assembly....................................................................................................................... 500-12

RIGHT OR LEFT SIDE FINAL DRIVE HOUSING-ASSEMBLY SPLITTINGREMOUNTING............................. 500-13


Splitting......................................................................................................................... 500-13
Remounting................................................................................................................... 500-17

DRIVING WHEEL SHAFT - OVERHAUL........................................................................................... 500-18


Demounting................................................................................................................... 500-18
Assembly....................................................................................................................... 500-20

BEVEL GEAR PAIR ADJUSTMENT.................................................................................................. 500-21

500-2 P/N3676163M1 Edition07-2004


SECTION500 - REAR DIFFERENTIAL AXLE
MAIN SPECIFICATIONS OF THE BEVEL GEAR PAIR AND DIFFERENTIAL
Bevel gear pair gear ratio: 9/44 = 1:4.88
Play between the flanks of the bevel gear pair gear teeth

(mm) 0.15 - 0.22

Type of differential with two planetaries

Mechanical control of diff lock


Electrohydraulic with mechanical
engagement

Adjustment of the bevel gear pair bearings and bevel gear pair
meshing play
see pages 20 - 26.

Thickness of the bearing adjuster rings and bevel gear pair 0.70 - 0.75 - 0.80 - 0.85 - 0.90 -
(mm)
meshing play (Sd, Ss, fig. 2) 0.95 - 1.00 - 1.10

Thickness of the pinion bearing adjuster rings (Sh1, fig. 2)


0.10 - 0.30 - 0.50 - 0.70 - 0.90 -
(mm)
1.10 - 1.30 - 1.50

P/N3676163M1 Edition 07-2004 5003


SECTION500 - REAR DIFFERENTIAL AXLE
DRIVING TORQUE VALUES

Driving torque values


PARTS TO TORQUE Thread
Nm kgm

Screws fixing transmission housing to clutch housing (Ci)........... - 117 - 129 11.9 - 13
Screw fixing cover to transmission housing PTO (C2)..................
-
20 - 25 2 - 2.5
Screw fixing bevel gear pair bearing support (C3)....................... - 135 - 149 13.8 - 15.2

Screw fixing transmission housing-final drive housing (C4).......... - 135 - 149 13.8 - 15.2

Screw fixing side final drive cover (C5)..................................... - 20 - 25 2 - 2.5

P/N3676163M1 Edition 07-2004 5003


SECTION500 - REAR DIFFERENTIAL AXLE

SECTION500 - REAR DIFFERENTIAL AXLE

DRIVING TORQUE VALUES


2LA00330

0^ SECTION500 - REAR DIFFERENTIAL AXLE 2

P/N3676163M1 Edition 07-2004 5003


SECTION500 - REAR DIFFERENTIAL AXLE

SECTIONS

2LA0331

2
Rear transmission-gearbox sections

Sd Adjuster shims. 6. Diff lock fork.


Sp1 Adjuster shims. 7. Diff lock rod.
Ss Adjuster shims. 8. Flange.
9. Taper bearing.
1. Bevel pinion.
10. Bevel ring
2. Taper bearing.
gear.
3. Taper bearing.
11. Differential
4. Nut
housing.
5. Diff lock hydraulic
12. Diff lock ring.
actuator.
13. Taper bearing.

1. Axle shaft. 5. Ball bearing.


2. Ball bearing. 6. Final drive gear.
3. Ball bearing. SECTIONS 7. Ball bearing.
4. Wheel hub.
SECTION500 - REAR DIFFERENTIAL AXLE

DESCRIPTION AND OPERATION.

The rear transmission transmits drive from the gearbox The differential has two planetaries and is providedwith a
mechanically engaged, electrohydraulically engaged diff
to the side final drives, by means of the bevel gear pair. lock.
The bevel gear pair is the type with helical toothing and The side final drives are the type with straight toothing
is supported by taper roller bearings. and are controlled by the bevel gear pair output axle
shaft, the same that control the main brakes.

TROUBLESHOOTING FOR THE BEVEL GEAR PAIR AND DIFFERENTIAL


Faults Possible causes Remedies

Noisy transmission when the Detach the rear transmission hous-


tractor is on the move, even with ing, replace the worn parts and
Crown wheels and plane- tary gears
the gears in neutral (not due to the correctly adjust the differential gears.
incorrectly adjusted or worn.
side final drives).
Remove the rear transmission housing
and replace the damaged parts.
Excessive play in the groove where
the axle shafts are shrunk on to
the crown wheels.

Noisy transmission when the


Some internal component is faulty or Detach the rear transmission housing,
tractor is on load and without load. defective. replace the worn parts and correctly
adjust the differential gear play.

Noisy transmission with over-


Insufficient coupling play between the
heating. pinion teeth and bevel gear pair. Remove the rear transmission housing
and correctly adjust the bearings that
support the ring bevel gear.

TROUBLESHOOTING FOR THE SIDE FINAL DRIVES


Faults Possible causes Remedies

Noisy side final drives when the Remove the side final drive housing
tractor is on the move, even with Some internal component is faulty and replace the damaged parts.
the gears in neutral. or defective.
Remove the side final drive housing
Excessive play in the groove where and replace the damaged parts.
the wheel axle shafts are shrunk
on to the side final drives.
SECTION500 - REAR DIFFERENTIAL AXLE

WHERE THE SEALANT IS APPLIED FOR THE GEARBOX-REAR TRANSMISSION HOUSING

< 0
SECTION 500 - REAR DIFFERENTIAL AXLE

4
The types of sealant to apply are indicated in section 100.

REAR TRANSMISSION HOUSING - OVERHAUL

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Demounting
Proceed in the following way to demount the parts:
1. Split the gearbox-rear transmission housing
(see section 400).
2. Split the mechanically engaged PTO (see section
600).

7
6
5
3. Unscrew the fixing screws (1) and remove the diff lock actuator (2).
4. Remove the spring ring (1) and take out the diff lock rod (2). Recover the fork and return spring (3) from
inside the transmission hous- ing.
5. Unscrew the fixing bolts (1) of the left-hand support of the ring bevel gear (1) and remove it.
Use and adequate puller (2) for this operation.
0^ SECTION500 - REAR DIFFERENTIAL AXLE <
6. Remove the ring bevel gear (1) from the gear- box-rear
transmission housing and recover the adjuster shims.

Assembly
WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Comply with the following recommendations when


remounting the gearbox-transmission housing.
Consult the illustrations on pages 7 and 8 in
order to position the various parts correctly.
Before remounting the housings, supports and
covers, thoroughly clean and degrease the cou-
pling surfaces and apply a strip of sealant about
2 mm in diameter as indicated in figure 4.
Apply the driving torques listed on page 4.

Adjust the pinion bearings as described on page


21.
Position the ring bevel gear inside the transmis-
sion housing. Mount the left-hand ring bevel
gear support.
Adjust the ring bevel gear bearings and the play
between the flanks of the bevel gear pair teeth
as described on page 21.
Mount the diff lock rod complete with fork and
return spring.
Mount the diff lock hydraulic actuator.
RIGHT OR LEFT SIDE FINAL DRIVE HOUSING-
ASSEMBLY SPLITTING REMOUNTING

Splitting

DANGER
Lift and handle all heavy parts with lifting
equipment of an adequate capacity.
Make sure that the units or parts are sup-
ported by appropriately sized harness and
hooks.
Make sure that there are no bystanders
near the load being lifted.

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Proceed as follows:
- Block the front wheels with chocks. 9

- Jack up the rear part of the tractor.


1. Unscrew the fixing bolts (1) and remove the
wheel.

2. Remove the pin (1) that fixes the connecting plug of


the stay that prevents side swing (2) and take out
the plug.

3. Remove the pins (1) that fix the connecting plugs of the stay
that prevents side swing (2) and take the plugs (3) out of
their relative housings.
4. Disconnect the anti-side swing stay (1).

5. Position a mechanical stand (1) under the rear


transmission (2), inserting a strip of wood
between the tractor and the actual stand itself.
Drain the oil from the transmission.

6. Remove the spring ring (1) anddisconnect the


power lift rod (2).

13
SECTION500 - REAR DIFFERENTIAL AXLE

7. Using the tool (1), unscrew the fixing


screws and disconnect the support
that fixes the anti- side swing chain
(2).

8. Unscrew the fixing bolts (1) of the platform.


10. Using a standard spanner, unscrew the three
accessible fixing bolts (1) of the platform sup- port.

9. Disconnect the hydraulic oil hose (1).

Old oil must be disposed of in compliance


with the current laws in merit.
11. Using a suitable tool, raise the mudguard (1) and
remove the rubber support (2).
13. Unscrew the fixing nuts (1) and remove the side final
drive (2).

12. Unscrew the plug (1) and drain the oil from the
side final drive.

Old oil must be disposed of in compliance


with the current laws in merit.

14. Work in a similar way to split the left side final drive, with the exclusion of the operations
required to split the power lift valve system.
SECTION500 - REAR DIFFERENTIAL AXLE

Remounting

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Remount the right side final drive housing on to the tractor, bearing the following recommendations in mind:
Before remounting the housings, supports and covers, thoroughly clean and degrease the cou- pling surfaces and
apply a strip of sealant about 2 mm in diameter as indicated in fig. 4.
Position the side final drive housing on the transmission housing and tighten the fixing screws.
Mount the platform support.
Install the rubber support.
Screw on the platform fixing bolts.
Connect the support that anchors the anti-side swing chain along with the relative stay.
Connect the power lift rod.
Screw on the drain plugs and pour hydraulic oil into the transmission and final drive housing. The prescribed
product and relative quantity is given in section 100.
Mount the rear wheel.
Remove the chocks from under the wheels.
DRIVING WHEEL SHAFT - OVERHAUL

Demounting
With the side final drive housing split from the rear
WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

transmission, proceed with the demounting opera-


tions as described below.
1. Unscrew the fixing screws (1) and remove the
closing cover (2).

2. Remove the closing seal (4) from the bearing of


the driving wheel shaft.

3. Remove the spring ring (1) that holds the driv-


ing wheel shaft and recover the float adjuster
shim.
SECTION 500 - REAR DIFFERENTIAL AXLE

4. Remove the driving


wheel shaft (1).

5. Remove the reduction gear (1) and recover the shim (2)
that adjusts the float of the gear itself.

6. Remove the spring ring (1) that holds the bear- ing of
the axle shaft and remove the axle shaft (2) complete
with bearing.
7. Remove the retention seal.

0^ SECTION500 - REAR DIFFERENTIAL AXLE <


C
o
m

Assembly

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

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.
Apply the driving torques listed on page 4.
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Mount the driving sheel shaft.
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.
SECTION500 - REAR DIFFERENTIAL AXLE

BEVEL GEAR PAIR ADJUSTMENT

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Proceed in the following way:


1. Take out the track (2) of the pinion bearing using
a suitable tool (1).

2. Mount the complete bearing on the pinion.


Measure dimension (Li) with a depth microme-
ter (1).
3. Read the writing on the pinion head and cor rect
the nominal dimension (L2).

4. Read dimension (L3) (1), stamped on the top


part of the gearbox-transmission housing.
0^
5.
SECTION500 - REAR DIFFERENTIAL AXLE <

The value of the shims (Sh^ to mount behind


the pinion bearing will be given by:
Sh
1= 3
L - (L
1 + L2)
where:
L1 = Dimension measured
L2 = Nominal dimension (correct).
L3 = Dimension stamped on the transmission
housing.
Round off to the lower figure.
Example:
L1 = 59.25 mm. Dimension stamped
L2 = 72.2 - 0.3 = 72.2 mm. Nominal
dimension (correct).
L3 = 133.88 mm. Dimension measured Sh1 =
133.88 - (72.2 + 59.25) = 2.43 mm (Adjuster
shim Shu page 3).
Round off to the lower figure.
6. Insert the calculated shims Sh1 (1) inside the
pinion bearing seat. Mount the bearing and the
pinion.

7.
To give the right preload to the taper bearing of
the pinion, tighten the nut (1) until a 1-6 - 1.8
Nm pinion rolling torque is obtained.
SECTION500 - REAR DIFFERENTIAL AXLE

8. Measure the rolling torque with a torque wrench


(1).

9. Insert a test shim Sh2 = 2.5 mm (1) behind the


track of the bearing of the right support of the
ring bevel gear.

34
10. Position the ring bevel gear (1) inside the gear-
box-transmission housing (2). Mount the left
support of the bevel gear pair without any
adjuster shims. Tighten the fixing screws of the
left support of the bevel gear pair until obtain-
ing a 1.9 - 2.1 Nm rolling torque.

11. The rolling torque can be measured on the pin-


ion locking nut by means of the torque wrench
(1).
SECTION500 - REAR DIFFERENTIAL AXLE

12. Use a thickness gauge (1) to measure the gap


(L) between the gearbox-transmission housing 37
and the left support of the ring bevel gear.
Adequately increase the test shim (Sh2) if gap
(L) is L = 0.

13. The total pack (St) of adjuster shims to insert


inside the left and right supports of the bevel
gear pair is given by:
St = Sh2-L
Round off to the lower figure.
14. Use a comparator (1) to measure the play (G)
between the flanks of the ring bevel gear teeth.
Take three measurements at 120 and calcu-
late the arithmetical average of the 3 readings.

15. A correct average play should be between 0.15


mm and 0.22 mm, thus an average 0.18 mm
will be considered for the successive calcula-
tions.
16. The ring bevel gear float (Z) will be given by:
Z = G - 0.18
where:
G = Dimension measured.
0.18 = Theoretic dimension.
SECTION500 - REAR DIFFERENTIAL AXLE

17. The left (Ss) and right (Sd) adjuster


shims to insert behind the taper
bearing of the left and right ring
bevel gear supports will be given
by:
Sd = St- Z
S
s = St d
-S

Round off to the lower figure within


0.5 mm.

18. Mount the ring gear supports with the calcu- lated adjuster shims and, as previously described, check the ring
gear-pinion rolling torque and the play between the flanks of the ring bevel gear teeth.
Example
St = 2.5 mm.
Theoretic dimension of the test shim.
L = 0.2 mm.
Dimension measured.
St = 2.5 - 0.2 = 2.3 mm.
Total adjuster shim.
Round off to the lower figure.
G = 0.38 mm.
Dimension measured.
0.18 mm
= Theoretic dimension.
Z = 0.38 - 0.18 = 0.2 mm.
Ring gear float.
Sd = 2.3 - 0.2 = 2.1 mm.
Adjuster shim on the right ring bevel gear support.
Ss = 2.3 - 2.1 = 0.2 mm.
Adjuster shim on the left ring bevel gear support.
Round off to the lower figure within 0.5 mm.
0^ SECTION500 - REAR DIFFERENTIAL AXLE <
SECTION 510
FRONT AXLE
SECTION 510 - FRONT AXLE
Q
INDEX

Description Page

MAIN SPECIFICATIONS ................................................................................................................ 510-3

DRIVING TORQUE VALUES.............................................................................................................510-4

SPECIFIC EQUIPMENT................................................................................................................... 510-5

SECTIONS................................................................................................................................... 510-6

DESCRIPTION AND OPERATION......................................................................................................510-9


Axle assembly .................................................................................................................. 510-9

Differential lock ................................................................................................................ 510-9

TROUBLESHOOTING FOR THE FRONT AXLE DIFF LOCK DEVICE ........................................................510-10

FRONT AXLE.............................................................................................................................. 510-11


Splitting.......................................................................................................................... 510-11
Remounting.....................................................................................................................510-13

FRONT AXLE DIFFERENTIAL AND BEVEL GEAR PAIR SUPPORT ..........................................................510-14


Splitting.......................................................................................................................... 510-14
Remounting.....................................................................................................................510-15

FRONT BEVEL GEAR PAIR - OVERHAUL..........................................................................................510-16


Demounting.................................................................................................................... 510-16
Bevel pinion bearing preload .............................................................................................510-17
Adjustment of the axial position of the bevel pinion...............................................................510-18
Pinion - ring gear play adjustment......................................................................................510-19
Ring gear bearing float adjustment ....................................................................................510-20

FRONT DIFF LOCK - OVERHAUL....................................................................................................510-22


Demounting.................................................................................................................... 510-22
Assembly........................................................................................................................ 510-23

WHEEL HUB - OVERHAUL.............................................................................................................510-24


Demounting.................................................................................................................... 510-24
Assembly........................................................................................................................ 510-25

FRONT FINAL DRIVE - SPLITTING REMOUNTING.............................................................................510-26


Splitting.......................................................................................................................... 510-26
Remounting.....................................................................................................................510-27

FRONT FINAL DRIVE - OVERHAUL ................................................................................................510-28


Demounting.................................................................................................................... 510-28
Assembly........................................................................................................................ 510-31

AXLE STEERING CYLINDER - SPLITTING REMOUNTING ...................................................................510-33


Splitting.......................................................................................................................... 510-33
Remounting.....................................................................................................................510-35

510-2 P/N3676163M1 Edition07-2004


MAIN SPECIFICATIONS
Type In spheroidal cast iron, pivoting at the center
SECTION
PARTS 510 - FRONT AXLE
TO TORQUE Driving torque values
within two supports
Nm kgm
Front drive engaging control Mechanical, by means of a lever
Screw fixing pinion support to the central housing (C1) 70 7.15
Drive transmission
Screw fixing side final drive housingBy
tocentral
the central housing
differential (C2)
and bevel gear pair 50 5.10

Steering cylinder cover fixing screw (C3) reduction units 25 2.55

Differential locks Screw fixing hub to kingpin (C4) 50 5.10

- type "Twin lock" with electrohydraulic control

- engaging phase at the same time as the rear differential

- disengagement by means of the brake pedals

Central bevel gear pair 19/41

Upper bevel gear pair 21/22

Lower bevel gear pair 11/45


DRIVING TORQUE VALUES
Maximum steering angle 55

Maximum swing angle 12

0^ SECTION 510 - FRONTAXLE (L

P/N3676163M1 Edition 07-2004 5103


SECTION 510 - FRONT AXLE

SPECIFIC EQUIPMENT
Code Description

001 DT MIS Lock nut wrench


002 DT MIS Pinion play adjuster tool

003 DT MIS Lock nut wrench

004 DT MIS Kingpin play adjuster tool

SECTION 510 - FRONT AXLE

SECTIONS
Central differential section

1. Transmission shaft coupling 13. Differential housing


2. Outer pinion taper roller bearing 14. Crown wheel
3. Inner pinion taper roller bearing 15. LH differential bearing
4. Bevel pinion. 16. Central bevel gear pair adjuster shims
5. Planetary 17. Side final drive housing
6. RH axle shaft. 18. Diff lock sleeve
7. Side final drive housing 19. RH axle shaft.
8. Central bevel gear pair adjuster shims 20. Diff lock
9. RH differential bearing 21. Central bevel pinion adjuster shims
10. Crown wheel 22. Pinion support
11. Bevel ring gear 23. Central bevel pinion bearing adjuster
12. Planetary pin nut
24. Seal

2LA0542

P/N3676163M1 Edition 07-2004 5103


SECTION 510 - FRONT AXLE

2LA0543

3
Split axle shaft section
1. Bevel gear pair housing 6. Vertical axle shaft support bearing
2. Side final drive housing 7. Cover
3. Horizontal axle shaft. 8. Horizontal axle shaft support bearing
4. Vertical axle shaft 9. Spring ring.
5. Pivot pin 10. Differential bearing

0^ SECTION 510 - FRONTAXLE <L

4
Section drawing of final drives and hubs
1. Vertical axle shaft support bearing 11. Pinion support bearing
2. Seal 12. Final drive ring bevel gear
3. Upper pivot taper roller bearing 13. Spring ring.
4. Lower pivot taper roller bearing 14. Outer bearing to support bevel gear
5. Taper roller bearing lock nut 15. Hub
6. Pivot pin 16. Seal
7. Final drive bevel pinion 17. Inner bearing to support bevel gear
8. Cover 18. Spacer
9. Vertical axle shaft 19. Spring ring.
10. Spring ring. 20. Side final drive housing

SECTION 510 - FRONT AXLE

DESCRIPTION AND OPERATION

Axle assembly
The front axle consists of a lockable central differ- ential, split rigid axle shafts, integral
pivot pins and final drives with bevel gear pairs in the hubs.
The differential assembly has four planetary gears and can be locked by means of a
hydraulically con- trolled clutch mechanism with frontal teeth.
Torque is transmitted from the differential to the final drives through the axle shafts, each
of which split by means of a pair of bevel gears, and coaxi- ally passes through the relative
pivot pin.
The steering housing is installed in front of the axle and, by means of linkages, turns the
hubs around the pivot pins.
The axle can swing around the horizontal axle as it is borne by two supports fixed to the
chassis.

Differential lock
In the locked position (A), the sleeve (1, fig. 5) with frontal toothing meshes with the
relative toothing on the differential housing.
Since the sleeve is grooved on the inside and thus enbloc with the axle shaft, the
differential housing and the lh axle shaft (and, consequently, the other axle shaft) are
enbloc with each other in this posi- tion.
Both axle shafts therefore spin at the same speed and the differential is locked.
Engagement is obtained by allowing fluid under pressure to flow to a hydraulic piston that
acts on the engaging fork.

In the unlocked position (B), the sleeve (1, fig. 6) is moved away from the toothing, thus
releasing the differential housing which continues to operate nor- mally.
Disengagement is obtained by relieving the pressure of the fluid that acts on the piston,
while a return spring moves the piston to the unlocked position and keeps it there.
0^ SECTION 510 - FRONTAXLE <L

TROUBLESHOOTING FOR THE FRONT AXLE DIFF LOCK DEVICE

Possible causes Remedies


Faults

The diff lock control switch is inefficient Replace the switch


The diff lock fails to engage

No power transmitted to the solenoid Make the electrical connection and


valve: connections disconnected, replace the defective parts
damaged or relay defective

Controlling solenoid valve jammed in Overhaul or replace the solenoid


the discharge phase valve

Oil leaks through the seals, with Replace the defective seals
consequent drop in pressure

Inefficient hydraulic circuit Overhaul the circuit

The diff lock fails to disengage Controlling solenoid valve jammed in Overhaul or replace the solenoid
the delivery phase valve

No power transmitted to the solenoid Make the electrical connection and


valve: connections disconnected, replace the defective parts
damaged or relay defective

Faulty release spring Replace the spring


FRONT AXLE
DANGER
Splitting Lift and handle all heavy parts with lifting
equipment of an adequate capacity.
Make sure that the units or parts are sup-
ported by appropriately sized harness and
hooks.
Make sure that there are no bystanders
near the load being lifted.

WARNING SECTION 510 - FRONT AXLE

<n Handle all parts with great care. Do not put 0^


your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
Proceed as follows:
1. Place chocks under the rear wheels.
2. Remove the spring pin (1) that fixes the PTO
shaft sleeve (2).
3. Move the PTO shaft sleeve (1) backwards and
disconnect it from the front axle (2).
SECTION 510 - FRONTAXLE

4. Unscrew the fixing screws (1) of the front axle.

9
5. Unscrew the screws (1) that fix the hose (2) from the power steering cylinder (3) and drain the fluid from the
power steering system.

6. Disconnect the hose (1) from the T union.

Old oil must be disposed of in compliance


with the current laws in merit.

7. Place a lift (1) under the front axle (2). Pass a


harness (3) under the front ballast and lift the
tractor until it splits from the front axle.
WARNING SECTION 510 - FRONT AXLE
Handle all parts with great care. Do not put
your hands or fingers between one part and
Remou the next. Wear approved safety garments
nting
such as goggles, gloves and safety
footwear.
Comply with the following instructions when fitting
the complete axle assembly back on to the tractor:
- Position the complete axle assembly under the tractor. Lower this latter until it touches the axle, then recover the
lifting rope.
- Fit the complete axle assembly back on the tractor and torque the fixing bolts.
- Connect the hose to the power steering cylinder and T union. Torque the bolts.
- Connect the PTO sleeve to the front axle.
- Fit the spring pin that fixes the PTO shaft sleeve to the front axle.
- Screw on the drain plugs and pour oil into the power steering system. The prescribed product and relative quantity
is given in section 100.
- Remove the chocks from under the wheels.

0^ SECTION 510 - FRONTAXLE <L

FRONT AXLE DIFFERENTIAL AND BEVEL GEAR


PAIR SUPPORT

Splitting

DANGER
Lift and handle all heavy parts with lifting
equipment of an adequate capacity.
Make sure that the units or parts are sup-
ported by appropriately sized harness and
hooks.
Make sure that there are no bystanders
near the load being lifted.

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Proceed as follows:
1. Remove the axle steering cylinder (1).

2. Remove both side housings (1).


SECTION 510 - FRONT AXLE

3. Remove the differential assembly (1) from the


central housing.

4. Unscrew the screws that fix the bevel pinion


support and remove the actual support itself
(1). Recover the spacer (2).

Remounting

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Remount the front bevel gear pair support bearing


the following recommendations in mind:
- Refer to figs. 2, 3 and 4.
O

- Apply the driving torques listed on page 4.


- Mount a new retention ring (1). Mount the
adjuster spacer (2) and then mount the bevel
pinion support (3).
- Proceed by remounting both side housings.
- Now remount the axle steering cylinder.

0^ SECTION 510 - FRONTAXLE <L


Proceed as follows:
1. Remove the seals (1). Unscrew the locking rings
WARNING
nut (2) with wrench 001 DT MIS and remove
Handle all parts with great care. Do not put
O
it.
your hands or fingers between one part and
FRONT BEVEL GEAR PAIR - OVERHAUL
the next. Wear approved safety garments
such as goggles, gloves and safety
Demounting footwear.
2LA0587
18

2. Remove the pinion (1) complete with inner


bearing rings.
3. Remove both the outer rings (1) from the sup-
port. Remove the inner ring from the pinion if
necessary.

19

20
SECTION 510 - FRONT AXLE

4. Remount the front bevel gear pair bearing the


following recommendations in mind:
Refer to figure 2.
Apply the driving torques listed on page 4.
Proceed by remounting the parts in the
following way:
5. If removed, mount the inner bearing ring on the
pinion side on the actual pinion itself, using an
adequate plug.

6. Mount the outer ring on the pinion side (1) and


grooved side (2), into the relative seats in the
support.

7. Mount the pinion into the support. Now mount the


inner bearing on the grooved side (1) and then
mount the lock nut (2).

2LA0592

23
Bevel pinion bearing preload
Proceed as follows:
1. Tighten the lock until until the prescribed pinion
bearing preload is obtained.
Pinion bearing rolling torque:
1.0 - 1.2 Nm
0"
SECTION 510 - FRONT AXLE n

Adjustment of the axial position of the bevel pinion


Proceed as follows:
1. Measure the distance between the pinion head and
bearing flange (dimension A).
2. Measure the thickness of the central housing wall
(dimension C).
3. Measure the inner diameter of the seat of the side
final drive housing (dimension D).
4. Establish the effective distance (dimension B)
between the pinion head and ring gear axis by
applying the following relation.
B = (D/2) + C - A mm

5. Establish the thickness of the spacer to apply


between the pinion support and central hous- ing by
applying the following relation.
S = 48 mm - B
Example:
D = 142 mm C = 24 mm A = 48.5 mm

obtains B = (142 : 2) + 24 - 48.5 = 46.5 mm thus S

= 48 - 46.5 = 1.5 mm
6. Mount calculated spacer S (1) and the pinion support (2) then tighten the screws to the pre- scribed torque
value.
SECTION 510 - FRONT AXLE

Pinion - ring gear play adjustment


Proceed as follows:
1. Fit the differential assembly (1) into the central
housing.

~0^{
)

2. Mount both the side housings (1), inserting a SP = 3 mm


spacer (2) and fitting four screws in a diagonal position
without torquing them.
3. Mount tool 002 DT MIS (1) on the grooved
pinion tang, then mount a centesimal compara-
tor in the indicated direction, in order to meas-
ure the play.

The measurement must be made about 25


mm from the pinion axis (distance (L)).

4. Tighten the screws of the side housing on the


ring gear side (shown by the arrows in the fig-
ure) in a uniform way while measuring the pin -
ion - ring gear play until the prescribed value
has been obtained.
Pinion - ring gear play 0.8 - 0.22 mm

It is advisable to use a thickness gauge to


maintain an even gap between the two
housings.

SECTION
Proceed 510 - FRONT AXLE
as follows:
1. Remove the complete pinion support to access
the differential.
5.
2. Use a thickness
Proceeding in a gauge
similar to measure
way, tightenresidue gap
the screws
^E37 Li-
of the side housing on the opposite side in an
6. uniform way
Establish in order
the value to annul
of shim theapplying
S1 by float of the
the
differential bearings.
following relation:
S1gauge
3. Use a thickness = SH to
- L1
measure residue gap
L2.
4. Establish the valve of shim S2 by applying the
following relation:
S2 = SH - L2
5. Remove the side housings and insert previously
calculated spacers with thickness S1 for the one
on the ring gear side and S2 for the one on the
side opposite the ring gear.
Ring gear bearing float adjustment
<L
SECTION 510 - FRONT AXLE
0^

6. Apply sealant along the indicated part of the


jointing edge between the side housing and
central housing.
7. Remount both side housings and tighten the
screws to the prescribed driving torque value.

35
8. Remount the pinion support with the spacer and
retention ring, then tighten the screws to the
prescribed driving torque value.
9. Mount the seal (1) on the pinion support (2)
using a suitable mallet and complying with the
indicated positions.

36

0^ SECTION 510 - FRONTAXLE <L


Proceed as follows:
1. Remove the left side housing.

FRONT DIFF LOCK - OVERHAUL

Demounting

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

\T

2LA0606

38
W)
39
2. Unscrew the locking screw (1) and remove the plug (4), the spring (3) and the counter-rod (2).

3. Unscrew the retainer screw (2). Tighten an M6 screw (3) on to the fork pin (1) and use it as a puller to
remove this latter as indicated.
4. Remove the fork (2) and sliding sleeve (1). Also remove the control plunger from the housing.
SECTION 510 - FRONT AXLE

Assem
bly

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Remount the front differential lock bearing the fol-


lowing recommendations in mind:
- Refer to fig. 2.
- Apply the driving torques listed on page 4.
- Mount a new retention ring and fit the plunger back into its housing.
- Mount the sliding sleeve along with the fork inside the side housing.
- Mount a new retention ring and fit the pin into the fork, complying with the position of the threaded hole as
indicated.
- Tighten the fork retainer screw.
- Mount the rod, the spring and the plug and lock in place with the screw.
- Check by hand to make sure that the device operates correctly.
- Proceed by remounting the left side housing.

0^ SECTION 510 - FRONTAXLE <L

WARNING
Handle all parts with great care. Do not put
WHEEL HUB - OVERHAUL
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Demounting
Proceed as follows:
1. Unscrew the hub fixing screws (1, fig. 41) and
remove the hub complete with bevel gear.
2. Remove the spring ring (1) and the spacer (2).

3. Remove the bevel gear (1) complete with bear-


ing using a suitable puller.

43
SECTION 510 - FRONT AXLE

4. Remove the inner spring ring (1) and then


remove the bearing (2) and seal (3) from the
relative housing.

Assembly

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

Remount the wheel hub bearing the following rec-


ommendations in mind:
Refer to figs. 3 and 4.
Refer to the driving torques listed on page 4.

Mount a new seal (1) using a suitable tool and


comply with the indicated position. Fill the cav-
ity between the seal lips with the prescribed type
of grease.
Mount the bearing in the seat using a mallet and
then mount the spring ring.
Mount the wheel hub and then mount the bear -
ing, the spacer and lastly the spring ring.
Apply sealant all along the jointing edge between
the hub housing and pivot pin, com- plying with
the indications in the figure.
Remount the complete wheel hub.

2LA0614

46

0^ SECTION 510 - FRONTAXLE <


FRONT FINAL DRIVE - SPLITTING
REMOUNTING

Splitting
Proceed as follows:
DANGER
Lift and handle all heavy parts with lifting
equipment of anWARNING
adequate capacity.
Make sure
Handle that the
all parts withunits
greatorcare.
parts
Doare
notsup-
put
ported
your by appropriately
hands sized one
or fingers between harness
part and
hooks.
the next. Wear approved safety garments
Make sure
such that theregloves
as goggles, are no andbystanders
safety
near the load being lifted.
footwear. 48
1. Remove the split pin (2) and the lock nut (1).

2. Remove the head from its seat using an appro- priate lever (1).
SECTION 510 - FRONT AXLE

Take care of the differential assembly,


which tends to be dragged out of the side
housing.

3. Remove the axle breather (only from the right),


then unscrew the fixing screws and remove the
side housing (1). Recover the adjuster spacer
(2).
49

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
Remounting
Remount the front final drive bearing the following recommendations in mind:
Refer to figs. 2 and 3.
Refer to the driving torques listed on page 4. Apply
sealant all along the jointing edge between the side
housing and central housing, complying with the
indications in the figure.

- Mount the adjuster spacer (1) in the relative seat in


the side housing (2), then mount this latter, ta king
care to center the differential bearing and then the
centering pins.
- Mount the steering head in place with a new split pin.
SECTION 510 - FRONTAXLE <L
0^

DANGER
Lift and handle all heavy parts with lifting
FRONT FINAL equipment
DRIVE - OVERHAUL
of an adequate capacity.
Make sure that the units or parts are sup-
ported by appropriately sized harness and
hooks.
Make sure that there are no bystanders
near the load being lifted.

52
Demounting
Proceed as follows:
1. Remove the wheel hub.
It is absolutely essential to replace the
plugs.

2. Remove the lower (1) and upper (2) plugs using a suitable punch.

3. Remove the spring ring (1).


SECTION 510 - FRONT AXLE

4. Remove the bearing and bevel pinion (1) using an


adequate tool. Also remove the bearing from the
pinion if necessary.

5. Remove the ring nut that locks the taper bear- ings with
wrench 003 DT MIS (1).

6. Support the pivot pin (1) in an adequate way, then


remove it using a lever. Tap in carefully with a plastic
mallet until the bearings have been freed. Remove both
the inner bearing rings.

7. Remove the dust guard ring (1), the seal (2), the
outer ring (3) of the upper bearing and the outer
ring (4) of the lower bearing from the pivot pin.
8. Remove the spring ring (1), using a pair of pli- ers
for inner spring rings equipped with appro- priate
extensions.

58
9. Remove the horizontal axle shaft (1) by lever- ing on
the bevel gear side. Remove the bearing if necessary.

10. Remove the vertical axle shaft (2) from above.


remove the bearing (1) if necessary.
SECTION 510 - FRONT AXLE
<n 0^
Remount the front final drive bearing the
following recommendations in mind:
Refer to figs. 3 and 4.

Assembly

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

62

Refer to the driving torques listed on page 4.


Mount the vertical axle shaft complete with
bearing.
Mount the horizontal axle shaft (1) complete
with bearing, pushing until the gears contact.
Now lock it in place with the spring ring.

Take care to ensure that the bearing is !


correctly mounted on the axle shaft and the
relative spring retainer ring on the side
housing.

- Mount the outer ring of the lower bearing (1)


and the upper bearing (2) in the pivot pin.
Now mount the upper bearing (3).

- Mount a new seal (1) and a new dust guard ring


(2) using a suitable tool and comply with the
indicated position. Fill the cavity between the
seal lips with the prescribed type of grease.
- Mount the pivot pin with the utmost care until it is
fully inserted. Now mount the inner ring of the
lower bearing (1) and tighten the lock nut (2)
without torquing.

Mount tool 004 DT MIS (1) on to the pivot pin.


Use a torque wrench to check that the rolling
torque of the bearings is within the prescribed
values.
Pivot pin bearing rolling torque: 15 - 20 Nm
- Adjust with the ring nut if this is not the case.

- Remount the wheel hub.


- Mount the bevel pinion complete with bearing and
fix it in place with the spring ring.
- Mount new closing plugs and apply sealant along
the jointing edges.

SECTION 510 - FRONT AXLE

AXLE STEERING CYLINDER - SPLITTING REMOUNTING

Splitting
Proceed as follows:
DANGER
Lift and handle all heavy parts with lifting
equipment of an adequate capacity.
Make sure that the units or parts are sup-
ported by appropriately sized harness and
hooks.
Make sure that there are no bystanders
near the load being lifted.

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.

1. Remove the split pin (2) and the lock nut (1) from both sides.
2. Remove the head from its seat using an appro- priate lever (1) on both sides.

68
3. Remove the steering arm (1) from both sides.

Do not touch the arm adjuster nut as this


EU3 lead to subsequent alignment oper- ations
being required.

4. Unscrew the screws from both sides of the cover


(1).

5. Remove the dust guard ring (1) and the seal (2)
from both covers.

The rod and the piston cannot be sepa-


rated.

6. Take out the complete cylinder (1), then remove the rod (2) from it. Remove the reten- tion rings (3) from the
piston if necessary.
WARNING SECTION 510 - FRONT AXLE
Remou
nting Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
Remount the steering cylinder bearing the following
recommendations in mind:
- Refer to figs. 2 and 3.
- Refer to the driving torques listed on page 4.

- Mount new retention rings on to the piston and


reassemble the steering cylinder.
- Apply sealant all along the jointing edge between the
central housing and cover, comply- ing with the
indications in the figure.

Mount a new dust guard ring (1) and a new seal (2)
using a suitable tool and comply with the indicated
position. Fill the cavity between the seal lips with the
prescribed type of grease, then mount the covers.
Remove the steering arms from both sides. Mount the
steering head from both sides and fix it in place with a
new split pin.
SECTION 510 - FRONT AXLE
SECTION 600
POWER TAKE-OFF

51036 P/N3676163M1 Edition07-2004


SECTION 600 - POWER TAKE-OFF
INDEX
Q
Description Page

MAIN SPECIFICATIONS ............................................................................................................... 600-3

DRIVING TORQUE VALUES........................................................................................................... 600-4

SECTIONS.................................................................................................................................. 600-5

DESCRIPTION AND OPERATION.................................................................................................... 600-6


Power take-off controlled directly by the main clutch ............................................................. 600-6

Power take-off synchronized with the gearbox....................................................................... 600-7

TROUBLESHOOTING FOR THE MECHANICALLY ENGAGED POWER TAKE-OFF........................................ 600-8

WHERE THE SEALANT IS APPLIED ON THE POWER TAKE-OFF COVER................................................. 600-9

MECHANICALLY ENGAGED POWER TAKE-OFF OVERHAUL ............................................................... 600-10


Demounting................................................................................................................... 600-10
Assembly....................................................................................................................... 600-12

600-2 P/N3676163M1 Edition07-2004


SECTION 600 - POWER TAKE-OFF

MAIN SPECIFICATIONS
540/540E RPM power take-off
Type (with two functions)...........................................

1) independent in relation to the


tractor's ground speed or
2) synchronised with the gearbox

Engagement and control............................................


mechanical, by means of a lever
installed under the steering
wheel and to the left of the
driver's position
Speed selection........................................................
by means of a lever installed on
the left side of the platform

Spinning direction (tractor viewed from the rear)........... clockwise

Engine rate with PTO at 540 RPM................................


(RPM) 2538

Engine rate with PTO at 540E RPM............................... (RPM) 1869

Diameter of the driven shaft on output spline shaft . . . 13/8" (6 splines)

Rotation rate with 540E RPM PTO synchronized with the (revs/wheel
11.075
gearbox .................................................................. turn)

SECTION 600 - POWER TAKE-OFF

DRIVING TORQUE VALUES

Driving torque values


PARTS TO TORQUE Thread
Nm kgm

PTO cover fixing screws (Ci) - 20 - 25 2 - 2.5


P/N3676163M1 Edition 07-2004 6003
PTO shield fixing screws (C2) M 8 x 1.25 25 2.6

2LA0373
P/N3676163M1 Edition 07-2004 6003
SECTION 600 - POWER TAKE-OFF

SECTIONS

2
Longitudinal section of the 540/540E power take-off

1. Sliding sleeve 7. Retention


2. Upper PTO shaft ring
3. Ball bearing. 8. 540 RPM
4. Rear transmission gear
housing 9. Meshing
5. Cover sleeve
6. PTO output shaft 10. 540 E RPM
gear
11. Ball
bearing.
DESCRIPTION AND OPERATION

The output shaft of the power take-off is


mounted in the rear part of the tractor and
transfers drive from the engine to the mounted
or towed imple- ments. It can either be
controlled directly by the engine (independent
PTO) or directly by the gear- box (PTO
synchronized with the tractor's ground speed).
All tractors are equipped with a two-speed PTO,
i.e. 540/540E RPM, with mechanical
engaging/disen- gaging control.

Power take-off controlled directly by the main clutch


Proceed in the following way to operate the inde-
pendent PTO:
- press the button (1) to release the clutch
lever (2);
- move the lever fully up until the disengaging
position is obtained;
- select the rotation speed for the spline shaft
by means of the lever (1, fig. 6);
- select the operating mode by moving the
lever (1, fig. 5);
- pull the lever (1) and press the button (2) to
release the lever;
- move the lever (1) fully down to the
4
engaging position.

In these conditions, operation is fully independent from the ground speed of the tractor. The operator can
therefore:
- stop the tractor without stopping the PTO;
- stop the PTO without stopping the tractor (by
disengaging the PTO clutch).
The direction in which the end part spins is clock-
wise, with the tractor viewed from the rear.
Just move the lever up (1, fig. 5) to disengage the
PTO.

Only keep the lever in the disengaging


position for the time it takes to make the 5
manoeuvres. Always keep the lever in the
engaged position during work.
SECTION 600 - POWER TAKE-OFF

AWARNING 6
Always disengage the PTO when you get off
the tractor.
Power take-off rates:
power take-off selected: 540 RPM (Excluding
North America)
- 540 RPM with engine at: 2538RPM
- 595 RPM with engine at: 2800RPM

power take-off selected: 540 E RPM


- 540 E RPM with engine at: 1869RPM

- 630 RPM with engine at: 2181RPM

Power take-off synchronized with the gearbox


The function whereby the power take-off is synchronized with the gearbox is used to tow trailers or implements
with drive transmitted to the wheels. It is also used for implements that must work in synchronism with the
ground speed of the tractor and that do not require
more than 40-45% of the tractor power. Only select
the 540 E speed with the synchronized PTO. Engage
the synchronized PTO when the tractor is at a
standstill.

Proceed in the following way to select the synchro-


nized PTO:
- stop the tractor but keep the clutch pedal
depressed; 7
- move the lever (1, fig. 7) up to disengage the
PTO clutch;
- select the 540 E speed; lever (1) back;
- push the lever (1, fig. 9) forwards to select the
synchronized PTO mode;
- move the lever (1, fig. 7) down to engage the
PTO clutch;

8
When the tractor is reversed and the syn !
chronized PTO is engaged, the PTO shaft will turn
in the opposite direction. Always remember to
disengage the PTO to pre- vent the implement
connected from being damaged.

Whatever speed gear is engaged, the PTO


output shaft spins 11.075 revolutions for
each turn of the rear wheels.

TROUBLESHOOTING FOR THE MECHANICALLY ENGAGED POWER TAKE-OFF


Possible causes Remedies
Faults
9
The spline shaft on the PTO output
Compare with the values given in the
slips with relative loss of speed. Wear on the clutch plate or on the
relative pages in sect. 18. Replace
pressure plate of the fly- wheel.
excessively worn parts and adjust the
PTO clutch lever badly adjusted.
clutch control lever.

It is difficult to select the PTO


The external control has hard- Lubricate the control levers. Adjust the
speed by means of the lever lever
ened or is badly adjusted. control.
(1, fig. 6);
SECTION 600 - POWER TAKE-OFF

WHERE THE SEALANT IS APPLIED ON THE POWER TAKE-OFF COVER

2LA0382

10
The types of sealant to apply are indicated in section 100.
MECHANICALLY ENGAGED POWER TAKE-OFF OVERHAUL

Demounting
Proceed as follows:
WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
1. Split the gearbox-rear transmission housing.
2. Unscrew the fixing screws (1) and remove the shield (2) from the PTO shaft.

3. Unscrew the fixing bolts (1) and remove the cover (2) from the PTO shaft.
4. Unscrew the locking screw (1) of the fork (2). Unscrew the plug (3), remove the spring (4) and the rod
retainer ball.
SECTION 600 - POWER TAKE-OFF

5. Remove the PTO speed selection rod (1).


Recover the pawl (1) positioned between the
speed selector rod and the PTO engaging rod.

6. Unscrew the locking nuts (1) of the fork that engages


the PTO (2) and remove it..

7. Remove the spring retention ring (1) and take


out the driving gear (2).

16

8. Remove the spring retention ring (1) that holds the


PTO shaft.
SECTION 600 - POWER TAKE-OFF

9. Remove the PTO shaft from the gearbox-trans-


mission housing along with the relative gears (1).

WARNING
Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
Assembly
Comply with the following recommendations when remounting the PTO:
Comply with fig. 2 when positioning the various parts;
Before remounting the housings, support and cover, thoroughly clean and degrease the cou- pling surfaces
and apply a strip of sealant about 2 mm in diameter as indicated in fig. 10.
Refer to the driving torques listed on page 4; Mount the PTO shaft complete with gears; Position the spring
retention ring of the PTO shaft;
Insert the driving shaft and position the spring retention ring;
Insert the lock the PTO engaging fork;
Mount the PTO speed selector rod with the rel- ative retainer pawl;
Position and lock the PTO speed engaging fork; Fit on the cover of the PTO;
Mount the shield of the PTO;
Remount the gearbox-rear transmission hous- ing.
SECTION 700
HYDRAULIC CIRCUITS - REAR POWER LIFT

0 SECTION700 - HYDRAULICCIRCUITS - REAR POWER LIFT 7


^
INDEX

Description

MAIN SPECIFICATIONS - REAR HYDRAULIC POWER LIFT................................................

SPECIFIC EQUIPMENT...............................................................................................

SECTIONS AND PERSPECTIVE VIEWS .........................................................................


SECTION 700

DESCRIPTION OF THE OPERATING MODE OF THE HYDRAULIC

POWER LIFT.............................................................................................................

700-9
Position control ...............................................................................................
Draft control ..................................................................................................
Mixed position and draft control.........................................................................
Floating position..............................................................................................

DESCRIPTION OF THE OPERATING MODE OF THE HYDRAULIC


POWER LIFTS VALVE SYSTEM . . . 700-13
Neutral phase..................................................................................................
SECTION 700
Lifting phase ..................................................................................................
Discharge phase..............................................................................................

POWER LIFT'S VALVE SYSTEM - OVERHAUL..................................................................


Demounting....................................................................................................
Assembly .......................................................................................................

VALVE SYSTEM OF THE HYDRAULIC POWER LIFT - HYDRAULIC


TESTS.....................................................................................................................
700-27
Check for leaks from the discharge valve ...........................................................
Checking and adjusting the cylinder safety valve..................................................
Non-return valve test ......................................................................................
Over-pressure valve setting test........................................................................
SECTION 700
POWER LIFT - ADJUSTMENTS ....................................................................................
Sensitivity adjustment .....................................................................................
Draft control adjustment ..................................................................................
Position control adjustment ..............................................................................

HYDRAULIC POWER LIFT - OPERATING PRESSURE TEST.................................................


Checking the valve pressure setting for the auxiliary
control valves..................................................................................................
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

MAIN SPECIFICATIONS - REAR HYDRAULIC POWER LIFT


Mechanical Hydraulic Power Lift

Make Landini

Operating modes Position/draft control intermix/floating mode

Hydraulic system Open-center type

Cylinders 2 single-acting

Dimensions (mm) 0 45 x 145 stroke

Over-pressure valve (bar) 185 - 190

Cylinder safety valve (bar) 200 - 205

Lifting capacity

At ball ends with lower links horizontal (kg) 1200

SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

SPECIFIC EQUIPMENT
Code Description

001 IDR MIS Valve system support for bench tests


002 IDR MIS High pressure pump for bench tests

003 IDR MIS Draft control adjuster lever

004 IDR MIS Pressure gauge union

P/N3676163M1 Edition 07-2004 7003


SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

SECTIONS AND PERSPECTIVE VIEWS

2LA0407

1
Longitudinal section of hydraulic power lift
1. Discharge valve ring nut 15. Valve spring
2. Discharge valve casing 16. Safety valve ball
3. Discharge valve spring 17. Valve stem
4. Discharge valve plunger 18. Stem spring
5. Servo valve spring
6. Cover a. Duct where oil arrives from pump
7. Valve system casing b. Pump outlet
8. Non-return valve ball c. Servo valve pilot duct
9. Over-pressure valve ball d. Servo valve piloting pressure chamber
10. Over-pressure valve adjuster plug e. Servo valve piloting outlet
11. Over-pressure valve spring f. Duct delivering oil to the cylinder
12. Servo valve g. Duct discharging oil from the lifting cylinder
13. Valve housing i. Maximum valve outlet
14. Safety valve adjuster plug m. Antishock valve outlet

0 SECTION700 - HYDRAULICCIRCUITS - REAR POWER LIFT 7


^
2
Perspective view of hydraulic power lift

1. Discharge valve ring nut 12. Servo valve


2. Discharge valve casing 13. Valve housing
6. Cover 14. Safety valve adjuster plug
7. Valve system casing 15. Valve spring
8. Non-return valve ball 16. Safety valve ball
9. Calibration valve ball 17. Valve stem
10. Over-pressure valve adjuster plug 18. Stem spring
11. Calibration valve spring 19. Adjuster lever
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

2LA0861

3
Perspective view of the main components

1. Position/draft control lever 7. Cylinder


2. Position control lever 8. Power lift unit
3. Auxiliary control valve lever 9. Control lever unit
4. Reaction spring 10. Hydraulic valve system
5. 11. Housing of the control lever
Third point Link unit
6.

P/N3676163M1 Edition 07-2004 700-7


0^ SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT <

2LA0791

4
Exploded view of the main components
1. Draft control lever 5. Link
2. Position control lever 6. Cylinder
3. Control lever unit 7. Casing of the control lever unit
4. Power lift unit 8. Hydraulic valve system
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

DESCRIPTION OF THE OPERATING MODE OF THE HYDRAULIC POWER LIFT

The hydraulic power lift may have four operating modes:


Position control Draft control Mixed control Floating position
Each of these four operating modes must be cho- sen to suit the type of job and the surface consist- ency of
the soil.

Position control
To work in the position control mode, move the draft control lever (1) up on the sector and estab- lish the work
depth with the position control lever (2).
The position control mode allows the implement to be set at a determined position at any point between the
highest and lowest settings, both in and out of the
soil, depending on the position to which the control 5
lever is set.
Lifting link movement in height is proportional to the
movement of the control lever.
The depth at which the implement works will not
change even if it encounters soil of a different con-
sistency (example: zone d = sandy soil; zone e =
compact soil; zone c = clayey soil).

6
0^ SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT 2

Draft control
To work in the draft control mode, move the posi- tion
control lever (1) fully up on the sector and establish the
work depth with the draft control lever (2). The draft control
mode allows the trac- tor's lugging power to be maintained
at a constant level, automatically varying the work depth of
the implement as the soil conditions change. In this
operating mode, the depth at which the implement works
may change to a considerable degree if it encounters soil of
a different consistency (e.g.: zone d = sandy soil; zone e =
compact soil), while the depth remains more or less uniform
if the soil is homogeneous (zone c = clayey soil), whether
the land is flat, or with hollows and hillocks.
Use of the draft control mode is of particular use
during work that requires considerable lugging
power carried out with mounted implements, since
these transfer most of this lugging power to the rear
wheels, thus increasing the tractor's wheel grip.
The lever (4) regulates the sensitivity of the
response in draft control mode since it increases or
reduces the travel the third point must make in
order to change from the neutral phase to the dis-
charge phase.
Maximum sensitivity will be obtained with the lever
(4) in the (+) position while the minimum sensitiv-
ity is obtained in the (-) position.

2LA0414

8
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

Mixed position and draft control


When work is carried out in the draft control mode on
irregular soil, there may be excessive variations to the
work depth which are unacceptable for culti- vation on
that type of ground.
In these conditions, the mixed position-draft control
mode should be used.
To work in this mode, dig the implement into the soil and
establish the required work depth as described for the
draft control mode. Once this depth has been reached,
lower the draft control lever (1) and gradually move the
position control lever (2) downwards in order to increase
the degree of position control. The power lift operates in
the draft control mode but meanwhile prevents the implement from digging excessively into softer soil and
producing an uneven job.
When the power lift is preset for the mixed position and draft control mode (intermix), the maximum and
minimum depths at which the implement works are limited in relation to the mean value (see zone d = sandy
soil; zone e = compact soil) since knob movement towards the position control set- ting reduces the sensitivity
of the draft control action and introduces part of position control.
The positions to which the lever can be set are as many as can be obtained in the space that sepa- rates the
two ends and its vicinity to one end or the other leads to a greater influence being excercised by the position or
draft control functions.
During work, the operator must find the best position for the selector lever in order to obtain the best
compromise between draft variation and depth.

10
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

Floating position
To work in the float mode, move both the levers
fully down (1 and 2, fig. 9).
The floating position allows the lift links to swing
freely.
The floating position is therefore used for all imple-
ments that must simply rest on the soil and follow
the contours of the ground, or for semi-mounted
implements that have specific components with
which they rest on the ground.
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

DESCRIPTION OF THE OPERATING MODE OF THE


HYDRAULIC POWER LIFT'S VALVE SYSTEM

Three phases always occur during power lift opera- tion, To make the descriptions clearer, these three phases will
regardless of whether it is used in the position control or therefore be illustrated individually. However, remember
draft control mode or with contempora- neous draft and that the three phases take place without any specific
position control (Intermix): order when the power lift operates, particularly in the
Valve system in the neutral phase draft control and Inter- mix modes.
Valve system in the lifting phase Valve
system in the discharge phase

Neutral phase to discharge into the housing through ducts (c) and
As soon as the engine is started, the pump (3) draws (e). This allows the oil from the pump to discharge
oil from the tank (1) through the filter (2) and sends into the housing through duct (b).
it through duct (a) where it encounters the valve Note that ducts (a) and (f) in the valve system are
stem (6) in the central position of its travel, which races made around the body (4) so that the oil can
shuts off the delivery to the control unit (c). reach the various valves. The oil in the ram (7) and
Meanwhile, the oil passes through duct (a) formed duct (f) is blocked by the discharge valve (13) which
inside the valve system, and reaches the check valve is shut, thus the circuit is tight.
(11) that supplies the ram (7). This remains closed The cylinder safety valve (12) protects the circuit
as oil from the pump cannot reach a suffi- ciently between the ram (7) and the discharge valve (13),
high pressure to open it owing to the lesser opening opening and discharging the pressure peaks cre- ated
resistance of the servo valve (10). This lat- ter is when the tractor jolts or when the implement strikes
able to open thanks to the open piloting hole (c) against the ground.
which allows the oil in the piloting chamber (d)

11
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

In figure 12, different colours are used to show the oil flows in the different operating conditions, in the neutral phase.

| | Supplied oil

| | Static oil

Discharged oil

2LA0418

12
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

Lifting phase As the servo valve begins to close, preventing the oil
When the operator uses the position control lever to from flowing into the tank, the pressure begins to
raise the implement, or when in draft control mode, rise until its value allows the oil from the pump to
the implement transmits a signal indicating that it open the check valve (1) and flow towards the ram
has encountered greater resistance in the soil, lever (7).
(8) moves away from the valve stem (6). This, Having reached the required height, the lever (8)
influenced by its spring (9), follows lever movement moves the valve to the neutral position.
towards the left, thus setting to the lifting phase. The rear part of the servo valve (10) is set to the
The discharge valve (13) remains closed during this discharge phase through ducts (c) and (e). Thus oil
movement. on the delivery opens the servo valve again and
Oil on the delivery from duct (a), can now reach the discharges into the transmission housing.
servo valve (10), the valve stem (6) and duct (c). The pressure in the supply duct consequently drops
Since the surface of this side of the servo valve is and the check valve (11) closes owing to the spring
larger than the one on the side of the duct (b), the and the higher pressure in the user circuit, thus
servo valve closes also thanks to the force exer- stopping the links from lifting.
cised by the spring.

2LA0419

13
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

In figure 14, different colours are used to show the oil flows
in the different operating conditions, in the lifting phase.

| | Pressurized oil

I| Discharged oil

2LA0420
14
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

Discharge phase is pushed back to the neutral position by its spring


When the links must lower, lever (8) pushes the (9). Affected by spring (14), the discharge valve (13)
valve stem (6) fully into the body of the valve sys- also returns to its hold position, gradually shutting off
tem. This manoeuvre also involves the discharge the oil flow towards the outlet and bringing the user
valve (13) which is moved and opened by the circuit to the tight status.
mechanical action of the valve system itself. As the links lower, the valve stem (6) keeps the servo
Valve (13) opening, sets ram (7) in communication valve (10) released thanks to duct (c) which is
with the outlet, through duct (g). discharging via duct (e). The oil delivered by the
Note that since the discharge valve (13) has a slid- pump thus discharges through the actual servo valve
ing cylinder, there will be no valve surging, the and duct (b).
advantage being that the links will lower in a regu- The adjuster device (15) allows the discharge valve
lar way. Moreover, throttle (16) limits the lowering (13) to move nearer or further from the valve stem
speed. (6) so as to increase or decrease the sensitivity of
Once the required height has been reached, the the power lift.
control lever (8) moves back and the valve stem (6)

2LA0421

15
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

In figure 16, different colours are used to show the oil flows in the different operating conditions, in the discharging
phase.

< 0^
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

Proceed as follows:
1. Split the power lift's
valve system.
POWER LIFT'S VALVE SYSTEM - OVERHAUL
WARNING
Demounting Handle all parts with great care. Do not put
your hands or fingers between one part and
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear. 19
17
2. Unscrew the bolts (1), remove the cover (2).
3. Unscrew the fixing screws (1) of the valve system (2) and remove this from its housing.

4. Lock the linkage housing of the valve system (3) in a vice and remove the Allen screw (1) that fixes the
valve system's pin shaft (2).
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

5. Release the shaft (1), remove it from the link- age


housing and take out the valve system's pin control
lever (2).

6. Release the Allen screw (1), loosen screw (2)


and remove the lever (3).

21

7. Unscrew the screws (1) and remove friction


ring support (2).

22

8. Unscrew the retainer plug (1) of the eccentric shaft.


SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

9. Remove the eccentric shaft (1).

10. Remove the plates (1) and the eccentric ring (2).

11. Remove the spring ring (1) that holds the lever (2).

12. Remove the lever (1) complete with the friction ring
support.
13. Remove the Allen screw (1) that fixes the shafts that
control the external linkages.
27

14. Remove the screw (6, fig. 24), the external lever (5, fig. 24) and then, in the following order.
the lever (3);
the shaft (2);
the spacer rollers (4);
the inner eccentric ring (1).
15. Hold the valve system firmly in a vice. Take all the
necessary precautions to prevent it from being
damaged.

16. Unscrew the screw (1) that retains the valve system
pin (2).
@ SECTION 700 - HYDRAULICCIRCUITS - REAR POWER LIFT

17.
Remove the pin (1) from the valve system and
recover the spring (2).

18. Remove the safety wire (1) from the over-pres-


sure valves (2) and the cylinder safety device.

19. Demount the over-pressure valve (1) and the


cylinder safety valve (2).

20. Demount the pilot valve (1).

35
21. Open the vice, turn the valve system through
180 and shut the vice again. Take all the nec-
essary precautions to prevent the components
from being damaged.
Use a special pin driver to remove the spring
pin (1) and sensitivity adjuster lever (2).

22. Unscrew the screws (1) that fix the upper cover
(2) and remove this.

23. Take out the discharge valve (1) using the rela- 37
tive tool.

24. Take out the non-return valve (1).

< 0^
SECTION 700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

Assembly

WARNING
Handle all parts with great care. Do not put
25. Demount the calibrated
your hands nozzle
or fingers (1). one part and
between
the next. Wear approved safety garments
such as goggles, gloves and safety
footwear.
Comply with the following recommendations when
remounting the power lift's valve system:
- C
o
m
p
l
y

w
i
t
h

t
h
e

i
l
l
u
s
t
r
a
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s

a
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d
e
s
c
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i
o
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s

g
i
v
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n

f
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t
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d
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m
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p
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a
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i
n

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t
o

p
o
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i
t
i
o
n

t
h
e

v
a
r
i
o
u
s

p
a
r
t
s
.
- Mount the calibrated nozzle.
- Insert the non-return valve.
- Insert the discharge valve.
- P
o
s
i
t
i
o
n

a
n
d

f
i
x

t
h
e

u
p
p
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r

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v
a
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s
y
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t
e
m
.
- M
o
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t

t
h
e

s
e
n
s
i
t
i
v
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t
y
a
d
j
u
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a
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e

r
e
l
a
t
i
v
e

s
p
r
i
n
g

p
i
n
.
- Mount the pilot valve.
- Mount the cylinder safety valve.
- Mount the over-pressure valve.
- Adjust the safety valve and pressure.
- L
o
c
k

t
h
e

p
o
s
i
t
i
o
n
s

o
f

t
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s

w
i
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t
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e

s
a
f
e
t
y

w
i
r
e
.
- Insert the pin with its relative spring.
- L
o
c
k

t
h
e

v
a
l
v
e

p
i
n

w
i
t
h

t
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e

r
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a
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c
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k

s
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.
- R
e
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t
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e
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a
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(
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n
g

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e

s
p
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r

r
o
l
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r
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)
.
- Mount the inner eccentric ring (rocker arm).
- M
o
u
n
t

t
h
e
o
t
h
e
r

e
x
t
e
r
n
a
l

l
e
v
e
r

(
t
a
k
e

c
a
r
e

w
h
e
n

p
o
s
i
t
i
o
n
i
n
g
a
s

b
o
t
h

l
e
v
e
r
s

m
u
s
t

p
o
i
n
t

t
o
w
a
r
d
s

t
h
e

v
a
l
v
e

s
y
s
t
e
m
)
.
- M
o
u
n
t

t
h
e

e
x
t
e
r
n
a
l

s
p
r
i
n
g

p
i
n

t
h
a
t

f
i
x
e
s

t
h
e

l
e
v
e
r
.
- M
o
u
n
t

t
h
e

i
n
t
e
r
n
a
l

A
l
l
e
n

s
c
r
e
w

t
h
a
t

f
i
x
e
s

t
h
e
s
h
a
f
t
s

t
h
a
t

c
o
n
t
r
o
l

t
h
e

e
x
t
e
r
n
a
l

l
i
n
k
a
g
e
s
.
- Mount the external draft transmission lever.
- M
o
u
n
t
t
h
e

f
o
r
k
,

t
h
e

f
r
o
n
t

e
c
c
e
n
t
r
i
c

r
i
n
g

a
n
d

t
h
e

o
t
h
e
r
c
o
n
n
e
c
t
i
o
n

f
o
r
k
.
- Fit the eccentric shaft into the fork hole.
- T
i
g
h
t
e
n

t
h
e

A
l
l
e
n

s
c
r
e
w

t
h
a
t

f
i
x
e
s

t
h
e

d
r
a
f
t

t
r
a
n
s
m
i
s
s
i
o
n

l
e
v
e
r
.
- Mount the friction ring support.
- Mount the position control lever.
- A
l
i
g
n

t
h
e

i
n
t
e
r
n
a
l

f
o
r
k
s

(
w
i
t
h

t
h
e

i
n
d
e
n
t
s

o
n

t
h
e

h
o
r
i
z
o
n
t
a
l

s
h
a
f
t

a
n
d

t
h
e

b
a
c
k
w
a
r
d

s
t
r
o
k
e

l
e
v
e
r
s
)
.
- M
o
u
n
t

t
h
e

f
i
x
i
n
g

s
c
r
e
w

o
f

t
h
e

p
o
s
i
t
i
o
n

c
o
n
t
r
o
l

l
e
v
e
r
.
- M
o
u
n
t

t
h
e
c
o
n
t
r
o
l

l
i
n
k
a
g
e

o
f

t
h
e

v
a
l
v
e

p
i
n

a
n
d

t
h
e

r
e
l
a
t
i
v
e
A
l
l
e
n

s
c
r
e
w
.
- P
r
o
t
e
c
t

t
h
e

s
u
r
f
a
c
e

i
n

c
o
n
t
a
c
t

w
i
t
h
t
h
e

u
p
p
e
r

c
o
v
e
r

w
i
t
h

s
i
l
i
c
o
n
e

a
n
d

f
i
t

t
h
e

c
o
v
e
r

i
t
s
e
l
f

o
n

t
o

t
h
e

l
i
n
k
a
g
e

h
o
u
s
i
n
g
.
- P
o
s
i
t
i
o
n

t
h
e

v
a
l
v
e
s
y
s
t
e
m

i
n

i
t
s

h
o
u
s
i
n
g

a
n
d

f
i
x

i
t

i
n

p
l
a
c
e

w
i
t
h

t
h
e

r
e
l
a
t
i
v
e

s
c
r
e
w
s
.
- Shut the valve system housing with its cover.
- N
o
w

f
i
t

t
h
e

v
a
l
v
e

s
y
s
t
e
m

b
a
c
k
o
n

t
o

t
h
e

p
o
w
e
r

l
i
f
t
.
V
A
L
V
E
S
Y
S
TE
M
O
F
T
H
E
H
Y
D
R
A
U
LI
C
P
O
W
E
R
LI
FT
-
H
Y
D
R
A
U
LI
C
TE
S
T
S

D
u
r
i
n
g

t
h
e
s
e

t
e
s
t
s
,

t
h
e

v
a
l
v
e

s
y
s
t
e
m

m
u
s
t

b
e

m
a
d
e

t
o

o
p
e
r
a
t
e

i
n

t
h
e

v
a
r
i
o
u
s

c
o
n
d
i
t
i
o
n
s

i
n

w
h
i
c
h

i
t

m
a
y

b
e

c
a
l
l
e
d

u
p
o
n

t
o

w
o
r
k

w
h
e
n

t
h
e

p
o
w
e
r

l
i
f
t

i
s
o
p
e
r
-

a
t
i
n
g

o
n

t
h
e

t
r
a
c
t
o
r
.
T
h
e
s
e

t
e
s
t
s

a
l
l
o
w

t
h
e
v
a
l
v
e
s

t
o

b
e

c
a
l
i
b
r
a
t
e
d
,

t
o

m
a
k
e

s
u
r
e

t
h
a
t

t
h
e
r
e
a
r
e

n
o

l
e
a
k
s

a
n
d

t
o

e
s
t
a
b
l
i
s
h

b
e
f
o
r
e
h
a
n
d

w
h
e
t
h
e
r
t
h
e

a
s
s
e
m
b
l
y

o
p
e
r
a
t
e
s

w
i
t
h
i
n

t
h
e

l
i
m
i
t
s

f
o
r

w
h
i
c
h
i
t

w
a
s

d
e
s
i
g
n
e
d

a
n
d

b
u
i
l
t
.
The following tests must be carried out:
C
h
e
c
k

f
o
r

l
e
a
k
s

f
r
o
m

t
h
e

d
i
s
c
h
a
r
g
e

v
a
l
v
e

I
n
s
p
e
c
t
i
o
n

a
n
d

a
d
j
u
s
t
m
e
n
t

o
f

t
h
e

s
a
f
e
t
y

v
a
l
v
e
C
h
e
c
k

f
o
r

l
e
a
k
s

f
r
o
m

t
h
e

n
o
n
-
r
e
t
u
r
n

v
a
l
v
e

o
n

t
h
e

u
s
e
r

d
u
c
t
I
n
s
p
e
c
t
i
o
n

a
n
d

c
a
l
i
b
r
a
t
i
o
n

o
f

t
h
e

o
v
e
r
-
p
r
e
s
-

s
u
r
e

v
a
l
v
e

Check for leaks from the discharge valve


1. Pl
ac
e
th
&

&

&

e 41
val
ve
sy
st
e
m
(C
)
in
to
ol
0
0
1
ID
R
M
IS
(A
)
an
d
po
siti
on
it
so
th
at
th
e
su
pp
ly
ho
les
ar
e
no
t
sh
ut
off
.
2. Co
nn
ec
t
th
e
hi
gh
pr
es
su
re
pu
m
p
ho
se
0
0
2
ID
R
M
IS
to
th
e
up
pe
r
un
io
n
(B
)
of
th
e
to
ol
(lif
tin
g
ra
m
du
ct)
.
3. Po
siti
on
a
sui
ta
bl
e
bo
lt
be
tw
ee
n
th
e
ba
se
of
th
e
to
ol
0
0
1
ID
R
M
IS
an
d
th
e
val
ve
st
e
m
(7,
fig
.
42
)
th
en
un
scr
ew
th
e
bo
lt
an
d
lift
th
e
st
e
m
un
til
its
en
d
is
ab
ou
t 4
m
m
aw
ay
fro
m
th
e
lo
we
r
su
rfa
ce
of
th
e
bo
dy
of
th
e
val
ve
sy
st
e
m.

4. O
p
e
r
a
t
e

t
h
e

p
u
m
p

a
n
d

m
a
k
e

s
u
r
e

t
h
a
t

t
h
e

d
i
s
-
c
h
a
r
g
e

v
a
l
v
e

(
3
,

f
i
g
.

4
2
)

d
i
s
c
h
a
r
g
e
s

t
h
e

o
i
l

f
r
o
m

t
h
e

d
u
c
t

(
G
,

f
i
g
.

4
2
)
.

I
f

t
h
i
s

f
a
i
l
s

t
o

o
c
c
u
r
,

t
u
r
n

t
h
e

s
e
n
s
i
t
i
v
i
t
y

l
e
v
e
r

c
l
o
c
k
w
i
s
e

u
n
t
i
l
t
h
e

v
a
l
v
e

o
p
e
n
s
.
5. C
o
n
t
i
n
u
e

t
o

o
p
e
r
a
t
e

t
h
e

p
u
m
p

a
n
d
b
e
g
i
n

t
o

s
l
o
w
l
y

t
u
r
n

t
h
e

s
e
n
s
i
t
i
v
i
t
y

l
e
v
e
r

i
n

t
h
e
a
n
t
i
-

c
l
o
c
k
w
i
s
e

d
i
r
e
c
t
i
o
n

t
o

s
t
a
r
t

c
l
o
s
i
n
g

t
h
e

v
a
l
v
e
.
6. S
t
o
p

t
h
i
s

o
p
e
r
a
t
i
o
n

a
s

s
o
o
n

a
s

o
i
l

s
t
o
p
s

f
l
o
w
i
n
g

f
r
o
m

d
u
c
t

(
G
,

f
i
g
.

4
2
)

a
n
d

t
h
e

p
r
e
s
s
u
r
e

g
a
u
g
e

s
h
o
w
s

t
h
a
t

t
h
e

p
r
e
s
s
u
r
e

i
s

i
n
c
r
e
a
s
i
n
g

(
p
o
s
i
t
i
o
n
1
)
.
Tur
n
th
e
lev
er
ag
ain
,
ab
ou
t
28
0
in
th
e
an
ti-
clo
ck
wi
se
dir
ect
ion
.
Thi
s
en
sur
es
a1
m
m
val
ve
co
ve
ra
ge
in
rel
ati
on
to
th
e
dis
ch
ar
ge
ga
ps
of
its
se
at
(p
osi
tio
n
2,
fig
.
42
).
No
w
op
er
at
e
th
e
pu
m
p
un
til
th
e
pr
es
sur
e
re
ac
he
s
th
e
val
ue
of
15
0
0^ SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT <
b
a
r
.
A
t

t
h
i
s

s
t
a
g
e
,

t
h
e

p
r
e
s
s
u
r
e

s
h
o
u
l
d

s
t
a
r
t

t
o
d
r
o
p

v
e
r
y

s
l
o
w
l
y
.

T
h
i
s

t
h
i
s

f
a
i
l
s

t
o

o
c
c
u
r
,

i
t

d
e
n
o
t
e
s

e
x
c
e
s
s
i
v
e

l
e
a
k
i
n
g

b
e
t
w
e
e
n

t
h
e

v
a
l
v
e

(
3
,

f
i
g
.

4
2
)

a
n
d

i
t
s

s
e
a
t

o
r

b
e
t
w
e
e
n

t
h
e

r
e
t
e
n
t
i
o
n

r
i
n
g
s
7.

(
4
,

f
i
g
.

4
2
)

a
n
d

t
h
e

b
o
d
y

o
f

t
h
e

v
a
l
v
e

s
y
s
t
e
m
.
T
h
e

m
a
x
i
m
u
m

l
e
a
k

t
o
l
e
r
a
t
e
d

a
t

p
r
e
s
s
u
r
e

o
f
1
5
0

b
a
r

a
n
d

a
t

t
e
m
p
e
r
a
t
u
r
e

o
f

2
5

3
0

i
s

c
m
3

w
i
t
h
i
n

m
i
n
u
t
e
s
.
I
f

t
h
e

v
a
l
u
e

m
e
a
s
u
r
e
d

i
s

h
i
g
h
e
r
,

d
e
m
o
u
n
t

t
h
e

v
a
l
v
e

a
n
d

r
e
p
l
a
c
e

t
h
e

r
e
t
e
n
t
i
o
n

r
i
n
g
s

(
4
,

f
i
g
.

4
2
)
,

t
h
e
n

r
e
p
e
a
t

t
h
e

t
e
s
t
.
R
e
p
l
a
c
e

t
h
e

d
i
s
c
h
a
r
g
e

v
a
l
v
e

(
3
,

f
i
g
.

4
2
)

a
n
d

i
t
s
s
e
a
t

i
f

t
h
e

f
a
u
l
t

p
e
r
s
i
s
t
s
.
Checking and adjusting the cylinder
SECTION700
safety- valve
HYDRAULIC CIRCUITS - REARtemperature
an ambient POWER LIFTof 25 - 30 C must not
1. Keep the pump connected to the same tool exceed 10 cc.
union and operate it until the cylinder safety 3. If the leaks exceed the tolerated value, check to
valve (6) opens. find out which component is leaking then,
It must open at the value of 185 - 190 bar. having eliminated the possibility of this being
If this fails to occur, adjust the valve by means the discharge valve which has already been
of the retention plug of the spring. checked, make sure that the cylinder safety
Tighten the plug to increase the setting value, valve (6, fig. 42) is tight by checking to see that
slacken it off to decrease the value. no oil flows from duct (M).
2. Once the valve has been adjusted, place a If oil is seen, its housing must be milled with an
graduated test tube under the valve system and adequate tool in order to re-create the sharp
keep the pressure in the circuit at 150 bar. The internal edge.
maximum leak tolerated in two minutes at

2LA0428

42

0 SECTION700 - HYDRAULICCIRCUITS - REAR POWER LIFT 7


^
Non-return valve test
Leaking can also be caused by the non-return valve
(5, fig. 42). Proceed in the following way to locate
the entity of the leak:
1. Remove the calibration valve which is in direct
communication with the duct that delivers oil to
the valve: this allows the oil to flow straight
through duct (L, fig. 42).
2. If oil flows through duct (L, fig. 42), mill its
housing with an adequate tool in order to re-
create the sharp edge on its housing, in com-
pliance with the following recommendations.
Use an upright drill to mill housings in order
to ensure that the mill operates in a per-
fectly perpendicular way.
The tool must turn between 100-200 RPM at
most.
3. Check the upper and intermediate retention
rings of the valve system if the leaks persist.

Do not attempt to re-create the seats by !


tapping on the balls as this would only enlarge
them.

Over-pressure valve setting test


This test must also be carried out with tool 001 IDR
MIS . Proceed as follows:
Start the
1. Move the pump
pump delivery
and check the to
hose pressure gauge
the lower to
union
see the pressure value at which
(D) and screw the closing plug on to union (B)the over-
pressure
used for thevalve (9, for
"Test fig.leaks
44) from
opens:
the The exact
discharge
value is 185 -
valve" (Fig. 41).190 bar.
If the
2. Fit necessary,
previouslyadjust the valve
removed by means
over-pressure of the
valve
3. spring
(9, fig.retention plug.
44) on the valve system. 43
4. Once the valve has been adjusted, maintain a
pressure of 150 bar in the circuit and, after
having set a graduated test tube in position,
make sure that the servo valve (8, fig. 44) leaks
no more than 100 cc. within the space of 2
minutes.
The part must be replaced if this limit is exceeded.
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

5. Make sure that no oil leaks from the duct (L) of the
calibration valve.
If necessary, mill the valve seat as described in the
previous section.
2LA0660

44
If oil leaks from duct (G), this is due to the play between the
upper part (X) of the stem (7) and the body of the valve

O OO
system (it will not be due to the discharge valve as this has
already been checked).
Oil leaking from duct (e) is due to the play between the
lower part (Y) of the stem and the body of the valve system.
This leak cannot be eliminated, but will not affect the
functionality of the system in any way.
However, it must not exceed 100 cc. within 2 min- utes.

P/N3676163M1 Edition 07-2004 70031


SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT
POWER LIFT - ADJUSTMENTS

The adjustments described below refer to the power lift


Q
installed on the tractor.

Sensitivity adjustment
Test conditions:
- Apply a weight of at least 100 kg to the power lift links;
- Turn on the engine and accelerate to a rate between
1000 and 1500 RPM;
- The position control and draft control levers must be in
the fully forward positions.
Proceed as follows:
1. Move the position control lever (1) to halfway along its
travel.

2. Partly remove the spring pin (1) that limits the travel of
the sensitivity control lever (2).

3. Turn the sensitivity control lever (1) clockwise to find


the point in which the discharge valve starts to open.
This will be denoted by the appearance of a rhythmic
swing from the lift links.
Proceed in the following way if the valve fails to open
after the lever has been fully turned in the clockwise
direction:

SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

4. Lower the lift links.


Slacken off the four screws (1) that fix the cover
(2) of the discharge valve;

700-32 P/N3676163M1 Edition07-2004

Turn the ring nut (1) anti-clockwise for about


6. Move
7. Turn
half the
athe
turn.
sensitivity
lifting control
lever
lever
(1) (1)
clockwise
beyondagain
half- until
way
5. Re-tighten
on the
the abovethe
sectorfour
so screws
mentioned (1, fig.
links48
thatconditions
the ) that
have
reach fix
been
an
the cover (2, fig.
intermediate
obtained. 48); of their travel again;
position
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT Q

700-314 P/N3676163M1 Edition07-2004


0^ SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT 2

8. Now turn the sensitivity lever (1) anti-clockwise until the


links stop swinging.
Stop turning the lever, turn off the engine and lower the lift
links.

9. Turn the lever (1) again about 30 mm in the


anti-clockwise direction measured at the ends of
the lever itself.

10. The position assumed by the lever therefore


constitutes the maximum sensitivity point of the
valve system.
Since this point can be located with the spring
pin on the lever against the lower right coun-
tersunk hex screw, after having loosened the
four countersunk hex screws, simultaneously
turn the lever and ring nut in order to carry the
maximum sensitivity point to the required posi-
tion.
11. Re-tighten the four screws (1, fig. 48) that fix
the cover (2, fig. 48) of the discharge valve.
12. Insert the spring pin (1, fig. 45) that limits the
travel of the sensitivity control lever (2, fig. 45).
13. Turn off the engine.
14. Remove the weight from the power lift links.
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

Draft control adjustment


Test conditions:
- Turn on the engine and accelerate to a rate between 1000 and 1500 RPM;
- The position control and draft control levers must be
in the fully forward positions.
Proceed as follows:
1. Move the position control lever (1) fully up.

2.

Slowly move the draft control lever (1) 50 - 55 mm


away from the position control lever (2). Make sure that the links
lift.

3. Make any adjustments required with the rod (1) if the


links fail to lift to the required extent.
0^ SECTION700 - HYDRAULICCIRCUITS - REAR POWER LIFT 2
4.
Fit tool 003 IDR MIS (1) on to the swinging
support and lift it to annul the the maximum
negative draft.

5. Slowly move the draft control lever (1) 15 - 20


mm away from the position control lever (2).
Make sure that the links lift.
6. If the measurement indicated in step 19 is not
correct, make any adjustments required with
the rod (1, fig. 56).
7. Move the draft control lever fully down. Make
sure that the links lower.

8. Lower tool 003 IDR MIS (1) so as to annul the


maximum positive draft travel. Make sure that
the links remain at a standstill in the low- ered
position.
Remove tool 003 IDR MIS (1).
9.
10. Turn off the engine.

SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

Position control adjustment


Test conditions:
Turn on the engine and accelerate to a rate between 1000 and 1500 RPM;

Proceed as follows:
11. The draft control (1) and position control (2) levers must be in the fully back positions.

700-36 P/N3676163M1 Edition07-2004


12. Make sure that the cylinder stem projection (1) is 135 - 140 mm from the base of the cylinder.
13. Proceed in the following way to adjust if this measurement is not correct.

14. Release the rod (2) by means of the check nut (1).

700-318 P/N3676163M1 Edition07-2004


SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

15. Unscrew the screw (1) that locks the adjuster rod
(2).
16. Turn the rod until the required adjustment has been
made.
17. Fix the rod in position and re-tighten the check nut
(3).
SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT

HYDRAULIC POWER LIFT - OPERATING


PRESSURE TEST

The operating pressure test must be conducted


whenever faults are encountered or when the trac-
tor is generally overhauled.
Remember that if the settings of the governor
valves in the circuit are too low, this will reduce the
lifting capacity of the power lift and the capacity of
the auxiliary control valves.
On the other hand, excessively high valve settings
create dangerous conditions of stress on all the
components involved.
At the end of the tests, use the relative adjusters to
ensure that the valve settings are correct.
The hydraulic tests must be conducted with the
engine at a rate of about 1200 RPM, with oil at a
temperature between 30 - 40 C, using the neces-
sary special tools and a set of pressure gauges.

Checking the valve pressure setting for the


auxiliary control valves
Insert union 004 IDR MIS (1) into a quick-con-
necting female half-coupling and connect it to the
pressure gauge (2) with 0 - 250 kg/cm2 scale.
Operate the lever of the valve system for the half- coupling
in question and activate the valve.
Check the pressure reading on the gauge. It must be 185 -
190 bar (188 - 193 kg/cm2).

64
SECTION 710

0 SECTION700 - HYDRAULIC CIRCUITS - REAR POWER LIFT 7


^ HYDRAULIC CIRCUITS - AUXILIARY CONTROL VALVES

0^ SECTION710 - HYDRAULICCIRCUITSAUXILIARY CONTROL VALVES <L


INDEX

Description Page

MAIN SPECIFICATIONS ................................................................................................................710-3


SECTION 710
DESCRIPTION AND OPERATION.....................................................................................................710-4
Description of the Circuit..................................................................................................... 710-5